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PARTS AND OPERATION MANUAL

MULTIQUIP INC..... PARTS DEPARTMENT:18910 WILMINGTON AVE. 800-427-1244CARSON, CALIFORNIA 90746 FAX: 800-672-7877310-537-3700 SERVICE DEPARTMENT:800-421-1244 800-835-2551FAX: 310-537-3927 FAX: 310-638-8046E-mail:[email protected] • www:multiquip.com


MQ POWERDCA-40SSI

WHISPERWATTTM

GENERATOR

PARTS LIST NO. 8051204

FINAL COPY

— DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 3

HERE'S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBERON-HAND WHEN CALLING

PARTS DEPARTMENT800/427-1244 or 310/537-3700FAX: 800/672-7877 or 310/637-3284

SERVICE DEPARTMENT800/835-2551 or 310/537-3700FAX: 310/638-8046

WARRANTY DEPARTMENT800/835-2551 or 310/537-3700FAX: 310/638-8046

MAIN800/421-1244 or 310/537-3700FAX: 310/537-3927


TABLE OF CONTENTS

Here's How To Get Help ................................................... 3Table Of Contents ............................................................ 4Parts Ordering Procedures .............................................. 5Rules for Safe Operation .............................................. 6-9Towing and Transportation ............................................. 10Trailer Safety Guidelines ........................................... 11-17Trailer Wiring Diagram .................................................... 18Electric Brake Troubleshooting ...................................... 19Hydraulic Brake Troubleshooting .................................... 20Operation and Safety Decals .................................... 21-22DCA-40SSI Specifications ............................................ 23General Information ....................................................... 24Major Components ........................................................ 25Dimensions ............................................................... 26-27Control Panel Descriptions ....................................... 28-29Engine Operating Panel Descriptions ....................... 30-31Output Terminal Panel Description ............................ 32-33Output Amperage Setup ........................................... 34-35Output Voltage Setup ................................................ 36-39Installation ................................................................ 40-41Pre Setup ................................................................. 42-45Load Application ............................................................ 46Generator Start-up Procedure .................................. 47-49Generator Shutdown Procedure ..................................... 50Maintenance ............................................................. 52-55Engine Wiring Diagram ............................................. 56-57Generator Wiring Diagram .............................................. 58Engine Troubleshooting ............................................. 60-61Generator/Engine Troubleshooting ................................. 62Explanation of Codes in Remarks Column .................... 64Suggested Spare Parts ................................................. 65

MQ POWER DCA-40SSIAC GENERATORGenerator Assembly .................................................66-67Control Box Assembly ..............................................68-71Engine & Radiator Assembly ....................................72-73Engine Operating Panel Assembly ...........................74-75Output Terminal Assembly ........................................76-77Battery Assembly .....................................................78-79Muffler Assembly .....................................................80-81Fuel Tank Assembly .................................................82-83Enclosure Assembly ................................................84-87Rubber Seal Assembly .............................................88-89Name Plate And Decals ...........................................90-91

ISUZU 4BG1 ENGINECylinder Head Cover Assembly ................................92-93Cylinder Head Assembly ..........................................94-95Cylinder Block Assembly .........................................96-97Oil Pan and Level Gauge Assembly .........................98-99Camshaft and Valve Assembly .............................. 100-101Crankshaft, Piston and Flywheel Assembly .......... 102-103Timing Gear and Flywheel Housing Assembly ...... 104-105Engine Mounting Assembly ................................... 106-107Inlet Manifold Assembly ........................................ 108-109Exhaust Manifold Assembly .................................. 110-111Ventilation Assembly ............................................. 112-113Water Pump and Corrosion Resistor Assembly ..... 114-115Thermostat and Housing Assembly ...................... 116-117Engine Water Piping Assembly .............................. 118-119Fan and Fan Belt Assembly .................................. 120-121Fuel Injection Assembly ........................................ 122-123Fuel Filter and Bracket Assembly ......................... 124-125Fuel Pump and Piping Assembly .......................... 126-127Oil Cooler and Oil Filter Assembly ........................ 128-129Oil Pump and Oil Strainer Assembly ..................... 130-131Oil and Vacuum Piping Assembly ......................... 132-133Electrical Control Assembly .................................. 134-135Battery Relay Assembly ........................................ 136-137Starter Component Assembly ............................... 138-139Inj. Pump Component Assembly ........................... 140-143Governor Component Assembly ............................ 144-147Feed Pump Assembly ........................................... 148-149Misc. Inj. Pump Assembly ..................................... 150-151Coupling Assembly ................................................ 152-153Accelerator Pedal Assembly ................................. 154-155Air Duct Assembly ................................................ 156-157Water Sedimenter Assembly ................................. 158-159Clutch Assembly ................................................... 160-161Switch and Relay Assembly .................................. 162-163

Terms and Condition of Sale — Parts ....................... 164

NOTE

Specification and part numberare subject to change withoutnotice.


PARTS ORDERING PROCEDURES

Get special freight allowanceswhen you order 10 or moreline items via FAX!**■■■■■ UPS Ground Service at no charge for freight

■■■■■ PS Third Day Service at one-half of actual freight cost

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price)do not count towards the 10+ line items.

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

For faxed orders only

UPSSpecial

Earn Extra Discounts whenyou order by FAX!

All parts orders which include complete part numbersand are received by fax qualify for the following extradiscounts:

Number ofline items ordered Additional Discount1-9 items 3%

10+ items** 5%

Now! Direct TOLL-FREE accessto our Parts Department!

Toll-free nationwide: 800-421-1244Toll-free FAX:

800/6-PARTS-7 • 800-672-7877

■■■■■ Dealer account number■■■■■ Dealer name and address■■■■■ Shipping address (if different than billing address)■■■■■ Return fax number■■■■■ Applicable model number■■■■■ Quantity, part number and description of each part■■■■■ Specify preferred method of shipment:

• UPS Ground

• UPS Second Day or Third Day*

• UPS Next Day*

• Federal Express Priority One (please provide us with your FederalExpress account number)*

• Airborne Express*

• Truck or parcel post

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Extra Fax Discount

Extra Fax Discount

Extra Fax Discount

Extra Fax Discount

Extra Fax Discount

for Domestic USAfor Domestic USAfor Domestic USAfor Domestic USA

for Domestic USA

Dealers OnlyDealers OnlyDealers OnlyDealers OnlyDealers Only


RULES FOR SAFE OPERATION

■ NEVER touch the hot exhaustmanifold, muffler or cylinder. Allowthese parts to cool before servicingengine or generator.

■ The engine of this generator requires an adequate freeflow of cooling air. Never operate the generator in anyenclosed or narrow area where free flow of the air isrestricted. If the air flow is restricted it will cause seriousdamage to the generator or engine and may cause injuryto people. The generator engine gives off DEADLY carbonmonoxide gas.

■ High Temperatures – Allow the engine to cool beforeadding fuel or performing service and maintenancefunctions. Contact with hot components can cause seriousburns.

Failure to follow instructions in this manualmay lead to serious injury or even death!This equipment is to be operated by trainedand qualified personnel only! This equipmentis for industrial use only.

The following safety guidelines should always be used whenoperating the DCA-40SSI portable generator:

GENERAL SAFETY

■ DO NOT operate or service this equipment beforereading this entire manual.

■ This equipment should not be operated bypersons under 18 years of age.

■ NEVER operate this equipment without properprotective clothing, shatterproof glasses, steel-toed boots and other protective devicesrequired by the job.

■ NEVER operate this equipment when not feelingwell due to fatigue, illness or taking medicine.

■ NEVER operate this equipment under theinfluence or drugs or alcohol.

■ NEVER use accessories or attachments, which are notrecommended by MQ Power for this equipment. Damageto the equipment and/or injury to user may result.

■ Manufacturer does not assume responsibility for anyaccident due to equipment modifications.

■ Whenever necessary, replace nameplate, operation andsafety decals when they become difficult read.

■ Always check the machine for loosened threads or boltsbefore starting.

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:

■ Always use extreme caution whenworking with flammable liquids. Whenrefueling, stop the engine and allow itto cool. DO NOT smoke around or nearthe machine. Fire or explosion couldresult from fuel vapors, or if fuel is spilledon a hot engine.

■ NEVER operate the generator in anexplosive atmosphere or near combustiblematerials. An explosion or fire could resultcausing severe bodily harm or evendeath.

■ Topping-off to filler por t isdangerous, as it tends to spill fuel.

■ Always refuel in a well-ventilated area,away from sparks and open flames.

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:




■ Backfeed to a utility system can cause electrocutionand.or property damage. Do not connect to anybuilding's electrical system except through an approveddevice or after building main switch is opened.

Never use damaged or worn cables whenconnecting power tools or equipment to thegenerator. Make sure power connectingcables are securely connected to thegenerator’s output terminals, insufficienttightening of the terminal connections maycause damage to the generator andelectrical shock.

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:DO NOT touch or open any of the belowmentioned components while thegenerator is running. Always allowsufficient time for the engine and generatorto cool before performing maintenance.

Radiator

1. Radiator Cap - Removing the radiator cap while theengine is hot will result in high pressurized, boiling waterto gush out of the radiator, causing severe scalding toany persons in the general area of the generator.

2. Coolant Drain Plug - Removing the coolant drain plugwhile the engine is hot will result in hot coolant to gushout of the coolant drain plug, therefore causing severescalding to any persons in the general area of thegenerator.

3. Engine Oil Drain Plug - Removing the engine oil drainplug while the engine is hot will result in hot oil to gushout of the oil drain plug, therefore causing severescalding to any persons in the general area of thegenerator.



■ NEVER touch output terminals during operation. This isextremely dangerous. Always stop the machine whencontact with the output terminals is required.



■ NEVER Run engine without air filter. Severe enginedamage may occur.

■ Always service air cleaner frequently to prevent carburetormalfunction.

■ Always disconnect the battery before performing serviceon the generator.

■ Always be sure the operator is familiar with proper safetyprecautions and operations techniques before usinggenerator.

■ Always store equipment properly when not in use.Equipment should be stored in a clean, dry location out ofthe reach of children.

■ DO NOT leave the generator running in the manual modeunattended.

■ DO NOT allow unauthorized people to operate thisequipment.

■ Always read, understand, and follow procedures inOperator’s Manual before attempting to operate equipment.

■ Refer to the Isuzu Engine Owner's Manual for enginetechnical questions or information.

Loading and Unloading (Crane)

■ Before lifting, make sure the generator's lifting hook issecure and that there is no apparent damage to thegenerator itself (loose screws, nuts and bolts). If anypart is loose or damaged, please take corrective actionbefore lifting.

■ Always drain fuel prior to lifting.

■ Always make sure crane or lifting device has beenproperly secured to the hook of guard frame on generator.

■ NEVER lift the machine while the engine is running.

■ Use adequate lifting cable (wire or rope) of sufficientstrength.

■ When lifting the generator, always use the balancedcenter-point suspension hook and lift straight upwards.

■ NEVER allow any person or animal to stand underneaththe machine while lifting.

■ When loading the generator on a truck, be sure to usethe front and back frame bars as a means to secure thegenerator during transport.

Battery

Never over fill the battery with water abovethe upper limit.


The battery contains acids that can cause injury to the eyesand skin. To avoid eye irritation, always wear safety glasses.Use well insulated gloves when picking up the battery. Usethe following guidelines when handling the battery:

1. DO NOT drop the battery. There is the possibility of riskthat the battery may explode.

2. DO NOT expose the battery to open flames, sparks,cigarettes etc. The battery contains combustible gasesand liquids. If these gases and liquids come in contactwith a flame or spark, an explosion could occur.

3. Always keep the battery charged. If the battery is notcharged a buildup of combustible gas will occur.

4. Always keep battery charging and booster cables in goodworking condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment,to avoid risk of a dangerous concentration of combustiblegases.

6. In case the battery liquid (dilute sulfuric acid) comes incontact with clothing or skin, rinse skin or clothingimmediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes incontact with your eyes, rinse eyes immediately withplenty of water, then contact the nearest doctor or hospital,and seek medical attention.


Transporting■ Always shutdown engine before transporting.

■ Tighten fuel tank cap securely.

■ Drain fuel when transporting generator over long distancesor bad roads.

■ Always tie-down the generator during transportation bysecuring the generator.

■ If generator is mounted on a trailer, make sure trailercomplies with all local and state safety transportationlaws. See page 10 for basic towing procedures.

Emergencies

■ Always know the location of the nearest fire extinguisherand first aid kit. Know the location of the nearest telephone.Also know the phone numbers of the nearest ambulance,doctor and fire department.


Maintenance Safety■ NEVER lubricate components or attempt service on a

running machine.

■ Always allow the machine a proper amount of time tocool before servicing.

■ Keep the machinery in proper running condition.

■ Fix damage to the machine immediately and alwaysreplace broken parts.

■ Dispose of hazardous waste properly. Examples ofpotentially hazardous waste are used motor oil, coolant,fuel, and fuel filters.

■ DO NOT use plastic containers to dispose of hazardouswaste.

■ DO NOT pour waste, oil, coolant or fuel directly onto theground, down a drain or into any water source.


To reduce the possibility of an accidentwhile transporting the generator on public roads, alwaysmake sure the trailer (Figure 1) that supports the generatorand the towing vehicle are in good operating condition andboth units are mechanically sound.

The following list of suggestions should be used when towingyour generator:

CAUTION :CAUTION :CAUTION :CAUTION :CAUTION :Towing Safety Precautions

Check with your county or state safetytowing regulations department before towingyour generator.

■ Make sure the hitch and coupling of the towing vehicleare rated equal to, or greater than the trailer "gross vehicleweight rating" (GVWR).

■ ALWAYS inspect the hitch and coupling for wear. NEVERtow a trailer with defective hitches, couplings, chainsetc.

■ Check the tire air pressure on both towing vehicle andtrailer. Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "SafetyChain".

DCA-40SSI — TOWING RULES FOR SAFE OPERATION

■ ALWAYS attach trailer’s safety chain to bumper of towingvehicle.

■ ALWAYS make sure the vehicle and trailer directional,backup, brake, and trailer lights are connected andworking properly.

■ The maximum speed for highway towing is 45 MPHunless posted otherwise. Recommended off-road towingis not to exceed 10 MPH or less depending on type ofterrain.

■ Place chocked blocks underneath wheel to preventrolling, while parked.

■ Place support blocks underneath the trailer’s bumper toprevent tipping, while parked.

■ Use the trailer’s hand winch to adjust the height of thetrailer, then insert locking pin to lock wheel stand in place,while parked.

■ Avoid sudden stops and starts. This can cause skidding,or jackknifing. Smooth, gradual starts and stops willimprove gas milage.

■ Avoid sharp turns to prevent rolling.

■ Remove wheel stand when transporting.

■ DO NOT transport generator with fuel in tank.

Figure 1. Generator with Trailer


Explanation of Chart:This section is to provide the user with trailer service andmaintenance information. The service and maintenanceguidelines referenced in this section apply a wide range oftrailers. Remember periodic inspection of the trailer will en-sure safe towing of the equipment and will prevent damageto the equipment and personal injury.

It is the purpose of this section to cover the major mainte-nance components of the trailer. The following trailer com-ponents will be discussed in this section:

BrakesTiresLug Nut TorquingSuspensionElectricalBrake Troubleshooting Tables

Use the following definitions with reading Table 1.1. Fuel Cell - Provides an adequate amount of fuel for the

equipment in use. Fuel cells must be empty when trans-porting equipment.

2. Braking System - System employed in stopping thetrailer. Typical braking systems are electric, surge, hy-draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is themaximum number of pounds the trailer can carry, in-cluding the fuel cell (empty).

DCA-40SSI — TRAILER-SAFETY GUIDELINES

4. Frame Length - This measurement is from the ballhitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender tofender.

6. Jack Stand - Trailer support device with maximumpound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters(175,185,205, etc.). The tire diameter must match thediameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’saxle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim mustmatch the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.Always use a torque wrench to tighten down the lugnuts. See Table 4 and Figure 5 or lug nut tightening andsequence.

13. Axle - Indicates the maximum weight the axle can sup-port in pounds, and the diameter of the axle expressedin inches (see Table 3). Please not that some trailershave a double axle. This will be shown as 2-6000 lbs.,meaning two axles with a total weight capacity of 6000pounds.

14. Suspension - Protects the trailer chassis from shockstransmitted through the wheels. Types of suspensionused are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are providedwith the trailer so the brake lights and turn signals canbe connected to the towing vehicle.

16. Application - Indicates which units can be employedon a particular trailer.

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:ALWAYS make sure the trailer is in goodoperating condition. Check the tires forproper inflation and wear. Also check thewheel lug nuts for proper tightness.


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DCA-40SSI —TRAILER-SPECIFICATIONS


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DCA-40SSI —TRAILER-SPECIFICATIONS


DCA-40SSI —TRAILER SAFETY GUIDELINES

BrakesIf your trailer has a braking system, the brakes should beinspected the first 200 miles of operation. This will allowthe brake shoes and drums to seat properly. After the first200 mile interval, inspect the brakes every 3,000 miles. Ifdriving over rough terrain, inspect the brakes morefrequently.

Electric BrakesElectrically actuated brakes (Figure 2) are similar tohydraulic brakes. The basic difference is that hydraulicbrakes are actuated by an electromagnet.Listed below are some of the advantages that electricbrakes have over hydraulic brakes:

Brake system can be manually adjusted to providethe corrected braking capability for varying road andload conditions

Brake system can be modulated to provide more orless braking force, thus easing the brake load on thetowing vehicle

Brake system has very little lag time between the timethe vehicle’s brakes are actuated and the trailer’s brakesare actuated

Brake system can provide an independent emergencybrake system

Remember in order to properly synchronize the tow vehicle’sbraking to the trailer’s braking, can only be accomplishedby road testing. Brake lockup, grabbiness or harshness isdue to lack of synchronization between the tow vehicleand the trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can bemade, the trailer brakes should be burnished-in by applyingthe brakes 20-30 times with approximately a 20 m.p.h.decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ampletime for brakes to cool between application. This allowsthe brake shoes to slightly be seated into the brake drumsurface.

Figure 2 displays the major electric brake components thatwill require inspection and maintenance. Please inspectthese components as required.

Electric Brake Adjustment1. Place the trailer on jack stands. Make sure the jack

stands are placed on secure level ground.2. Check the wheel and drum for free rotation.3. Remove the adjusting hole cover from the adjusting

slot at the bottom brake backing plate.4. With a screwdriver or standard adjusting tool, rotate

the star wheel of the adjuster assembly to expand thebrake shoes.

5. Adjust the brake shoes outward until the pressure ofthe lining against the wheel drum makes the wheeldifficult to turn.

6. Rotate the star wheel in the opposite direction until thewheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailerto the ground.

8. Repeat steps 1 through 6 on the remaining brakes.


DCA-40SSI — TRAILER SAFETY GUIDELINES

Hydraulic/Air/Surge BrakesHydraulic brakes (Figure 3) should not require any specialattention with the exception of routine maintenance suchas shoe and lining replacement. These brakes can beadjusted in the same manner as electric brakes. Brakelines should be periodically checked for cracks, kinks, orblockage.

Figure 3 below displays the major hydraulic/air/surge brakecomponents that will require inspection and maintenance.Please inspect these components as required using steps1 through 6 as referenced in the electric brake adjustmentssection.

Figure 2. Electrical Brake Components

Figure 3. Hydraulic Brake Components


Tires/Wheels/Lug NutsTires and wheels are a very important and criticalcomponents of the trailer. When specifying or replacing thetrailer wheels it is important the wheels, tires, and axle areproperly matched.

CAUTION:DO NOT attempt to repair or modify awheel. DO NOT install in inner tube tocorrect a leak through the rim. If the rimis cracked, theair pressure inthe inner tube

may cause pieces of the rim toexplode (break off) with great forceand cause serious eye or bodilyinjury.

Tire Wear/InflationTire inflation pressure is the most important factor in tire life.Pressure should be checked cold before operation DO NOTbleed air from tires when they are hot. Check inflationpressure weekly during use to insure the maximum tire lifeand tread wear.Table 2 (Tire Wear Troubleshooting) will help pinpoint thecauses and solutions of tire wear problems.

CAUTION:

NOTE

ALWAYS wear safety glasses when removingor installing force fitted parts. Failure to complymay result in serious injury.

SuspensionThe leaf suspension springs and associated components(Figure 4) should be visually inspected every 6,000 miles forsigns of excessive wear, elongation of bolt holes, andloosening of fasteners. Replace all damaged parts(suspension) immediately. Torqued suspension componentsas detailed in Table 3.

DCA-40SSI — TRAILER SAFETY GUIDELINES

Figure 4. Major Suspension Components


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Lug Nut Torque RequirementsIt is extremely important to apply and maintain proper wheelmounting torque on the trailer. Be sure to use only thefasteners matched to the cone angle of the wheel. Properprocedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.2. Torque all lug nuts in sequence. See Figure 5. DO NOT

torque the wheel lug nuts all the way down. Tighteneach lug nut in 3 separate passes as defined by Table 4.

3. After first road use, retorque all lug nuts in sequence.Check all wheel lug nuts periodically.

NOTE

NEVER use an pneumatic air gun totighten wheel lug nuts.

DCA-40SSI —TRAILER SAFETY GUIDELINES

Figure 5. Wheel Lug Nuts Tightening Sequence


NOTE:LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

DCA-40SSI —TRAILER-WIRING DIAGRAM


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DCA-40SSI —TRAILER-BRAKE TROUBLESHOOTING


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DCA-40SSI —TRAILER-BRAKE TROUBLESHOOTING


DCA-40SSI — GENERATOR DECALS

The DCA-40SSI generator is equipped with a number of safety decals. These decals are provided for operator safety andmaintenance information. The illustration below and on the preceding page show the decals as they appear on themachine. Should any of these decals become unreadable, replacements can be obtained from your dealer.


DCA-40SSI — GENERATOR DECALS


DCA-40SSI — SPECIFICATIONS

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DCA-40SSI — GENERAL INFORMATION

DCA-40SSI FAMILIARIZATION

Generator

The MQ Power Model DCA-40SSI is a 26 kW generatorthat is designed as a high quality portable (requires a trailerfor transport) power source for telecom sites, lightingfacilities, power tools, submersible pumps and otherindustrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:TachometerWater Temperature GaugeOil Pressure GaugeCharging Ammeter GaugeFuel level gaugeEngine Speed ControlPre-Heat ButtonPanel LightPanel Light SwitchStarter /Preheat Switch

Generator Control Panel

The “Generator Control Panel” is provided with the following:Output Voltage Adjustment KnobFrequency Meter (Hz)AC Ammeter (Amps)AC Voltmeter (Volts)Ammeter Change-Over SwitchVoltmeter Change-Over SwitchVoltage Regulator

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

Three 120/240V output receptacles, 50 ampTwo 120V input receptacles, 20 amp3 Load Circuit Breakers 240/120V @50 amps2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:Main Circuit Breaker 110 ampsOver-Current Relay

Engine

The DCA-40SSI is powered by a 4 cycle, water cooled,turbocharged Isuzu 4BG1 diesel engine. This engine isdesigned to meet every performance requirement for thegenerator. Reference Table 7, page 23 for enginespecifications.

In keeping with Multiquip's policy of constantly improvingits products, the specifications quoted herein are subject tochange without prior notice.

The basic controls and indicators for the DCA-40SSIgenerator are addressed on the following pages.

Mechanical Governor SystemThe mechanical governor system control the RPM of theengine. When the engine demands increase or decrease,the mechanical governor system regulates the frequencyvariation to ±1.5%. The electronic governor option in-creases frequency variation to ±.25%.

Open Delta Excitation System

The DCA-40SSI generator is equipped with the state of theart "Open-Delta" excitation system. The open delta systemconsist of an electrically independent winding wound amongstationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, thepower to the Automatic Voltage Regulator (AVR) is suppliedfrom the leads parallel connections of B&C. When loadsincrease, the AVR switches and accepts power from leadsA&D. The output of leads A&D increase proportionally withload. This of adding the voltages to each phase providesbetter voltage response during heavy loads.

The connections of the AVR to the AC output windings arefor sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitationcurrent, offering maximum motor starting capabilities. Theexcitation does not have a "fixed ceiling" and respondsaccording the demands of the required load.


DCA-40SSI — MAJOR COMPONENTS

Figure 6. Major Components


DCA-40SSI — DIMENSIONS (SIDE AND BACK)

Figure 7a. Dimensions


DCA-40SSI — DIMENSIONS (TOP AND FRONT)

Figure 7b. Dimensions


DCA-40SSI — CONTROL PANEL

Figure 8. Control Panel


DCA-40SSI — CONTROL PANEL

The definitions below describe the controls and functions ofthe DCA-40SSI " Control Panel " (Figure 8).

1. Main Circuit Breaker – This three-pole, 110 amp mainbreaker is provided to protect the UNV voltage outputterminals from overload.

2. AC Ammeter – Indicates the amount of current theload is drawing from the generator.

3. Frequency Meter – Indicates the output frequency inhertz (Hz). Normally 60 Hz ±1 Hz .

4. AC Voltmeter – Indicates the single phase outputvoltage present at the UNV terminals.

5. Voltage Regulator Control – Allows manualadjustment of the generator’s output voltage.

6. Ammeter Change-Over Switch – This switch allowsthe AC ammeter to indicate the current flowing to theload connected to any phase of the output terminals, orto be switched off.

7. Voltmeter Change-Over Switch – This switch allowsthe AC voltmeter to indicate phase to phase voltagebetween any two phases of the output terminals or tobe switched off.


DCA-40SSI — ENGINE OPERATING PANEL

Figure 9. Engine Operating Panel


The definitions below describe the controls and functions ofthe DCA-40SSI " Engine Operating Panel " (Figure 9).

1. Fuel Gauge - Indicates amount of diesel fuel available.

2. Tachometer – Indicates engine speed in RPM’s for 60Hz operation. This meter should indicate 1800 RPM’swhen the rated load is applied. In addition a built in hourmeter will record the number of operational hours thatthe generator has been in use.

3. Charging Ammeter Gauge – Indicates the currentbeing supplied by the engine’s alternator which providescurrent for generator’s control circuits and batterycharging system.

4. Water Temperature Gauge – During normal operationthis gauge be should read between 165o to 215o.

5. Oil Pressure Gauge – Normal operation should be about25 psi. When starting the generator the oil pressuremay read a bit higher, but after the enginewarms up the oil pressure should returnto normal.

6. Starter Switch- Use key to preheat,start and stop engine.

7. Pre-Heat Button – Press hold this buttonuntil the preheat lamp is lit (ON).

DCA-40SSI — ENGINE OPERATING PANEL

9. Panel light switch- When activated, will turn on controlpanel light.

10. Panel light - Normally used in darkplaces or at night. When activated, panelwill luminate. When the generator is notin use, turn the panel light switch to the‘OFF’ position.

8. Engine speed Handle- This handle willchange the speed of the engine from highto low.


DCA-40SSI — OUTPUT TERMINAL PANEL

Output Terminal PanelThe output control panel is located on the rear (control panel)end of the generator. The UNV lugs are protected by a faceplate cover that can be secured in the close position by apad lock.

120 Volt ReceptacleOne GFCI Duplex NEMA 5-20R (120V, 20 Amp) receptacleis located on the output terminal. This receptacle can beused anytime the generator is in operation. The receptacleis controlled by the circuit breaker located on the controlpanel.The reset button will reset the receptacle after being tripped.Pressing the :Test Button” (Figure 8) in the center of thisreceptacle will check the GFCI function. The receptacleshould be tested at least once a month.

Figure 10. GFCI Test Button

Connecting LoadLoads can be connected to the generator by the UVWO lugs orthe duplex receptacles. (See figure 3). Make sure to read theoperation manual before attempting to connect a load to thegenerator.

Maximum OutputThe entire load connected to the UNV Lugs, all four slots in theduplex receptacles, and the must not exceed 37.4 kW instandby or 36 kW in prime output.

Generator GroundingMake sure to ground the generator in EVERY applicationprior to connecting a load. Generators are NOT groundedjust because they are mounted on trailers or other vehiclesthat are on rubber tires. See page X for further details.

Twist Lock Dual Voltage Receptacles - To use thesereceptacles, place the voltage selector switch in the singlephase 240/120 voltage position and adjust the outputvoltage to 240 volts with the voltage regulator on theControl Panel (Figure 8, page 28). Place the voltmeterchange-over switch to the U-W position and the ammeterchange-over switch to the U or W to read the output.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 110 amp,main circuit breaker is provided to protect the UVWO outputterminals from overload. In addition two single-pole, 20 ampGFCI circuit breakers are provided to protect the GFCIreceptacles from overload. Three 50 amp load circuitbreakers have also been provided to protect the load side ofthe generator from overload. Make sure to switch ALL circuitbreakers to the "OFF" position prior to starting the engine.

Generator GroundingMake sure the generator is properly grounded beforeapplying load. Generators are NOT considered groundedwhen mounted on a trailer.

Figure 11. Load Application


DCA-40SSI — OUTPUT TERMINAL VOLTAGE SELECTION

DCA-40SSI

Legs O and Ground areconsidered Bonded Grounds.

NOTE

Figure 12. Output Panel Location


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Output Terminal Panel Available VoltagesA wide range of voltages are available to supply load tomany different applications. Voltages may be selected byusing the voltage selector switch and depending how youhookup your hard wire connection to the generator. To obtainsome of the voltages listed, fine adjustment with the voltageregulator on the control panel is necessary. See Table 8 foravailable voltages the generator will supply.

CAUTION :

NEVER switch Voltage Selector Switchposition while the engine is engaged.

Voltage Selector Switch Locking ButtonThe voltage selector switch has a locking button to protectthe generator and generator load from being switched whilethe engine is running. To lock the voltage selector switch,press in the red button located on the voltage selector switch,and use a pad lock to hold it into this position.

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Maximum AmpsTable 9 shows the maximum amps the generator will pro-vide. Do not exceed the maximum amps listed.

Over Current RelayAn over current relay is connected to the circuit breaker.During an over current situation, both the circuit breaker andthe over current relay will trip. If the circuit breaker can notbe reset, the reset button on the over current relay must bepressed. The over current relay is located inside the controlbox.

DCA-40SSI — OUTPUT AMPERAGE SETUP


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Receptacle UseWhen the UVWO terminals are providing power, the recep-tacle power availability will decrease. Do not exceed recep-tacle power as listed on Table 10.

How To Read The Output Terminal Gauges.The gauges (Figure 15 and 17) and change-over switcheson the control panel DO NOT effect the generator output.They are to help observe how much power is being suppliedat the UVWO legs.

When the voltage selector switch is in the 240/120V posi-tion (Figure 13), place the AC voltmeter change-over switchto the W-U position (Figure 14) and the AC ammeter change-over switch to the U or W position (Figure 16) to read theoutput on the selected leg.

A

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Figure 13. Voltage Selector Switch 240/120V SinglePhase Position

Figure 14 and 15. AC Voltmeter Change-over switchand Voltmeter Gauge

Figure 16 and 17. AC Ammeter Change-over Switchand Ammeter Gauge

When using plural single phasevoltages, make sure to balancethe load on each of the singlephase legs.

NOTE

DCA-40SSI — OUTPUT AMPERAGE SETUP


240/120V Hard Wire HookupWith the voltage selector set and locked at ‘single phase240/120’ and using single phase 120 volts, the generatorwill provide three legs available with 100 amps each on threedifferent circuits (Figure 18).

480/240V Hard Wire Hookup

With the voltage selector set and locked at ‘3 phase 480/277’ (Figure 19) and using the 3-phase 240 hookup, it willprovide one circuit available at 108 amps with any two wiresplus the ground (Figure 20).

When using the 3-phase 480 volts hookup, it will provideone circuit available at 50 amps with all three wires plusground.

Figure 19. Voltage Selector Switch 480/277V Three PhasePosition

Figure 18. Hard Wire Hookup at 240/120V Position

Figure 20. Hard Wire Hookup at 480/240V Position

DCA-40SSI — OUTPUT VOLTAGE SETUP


Voltage Selector Switch- 3 Phase 480/277V PositionThe following are additional voltages available when the volt-age selector switch is in the ‘3 phase 480/277V’ position.

3 Phase, 480V, 440V, or 416 VoltThis setting can provide 3-phase power at 480, 440, or 416volts. After hooking up the hard wires to the lugs as shownin Figure 22, 480 volts can be obtained with the voltageregulator knob turned toward maximum; 440 volts can beobtained with the voltage regulator knob is turned down; and416 volts can be obtained with the voltage regulator knob isat the lowest setting.

Single Phase: 480V, 440V, or 416 VoltThis setting can provide single phase power at 480, 440, or416 volts. After hooking up the hard wires to the lugs asshown in Figure 23, 480 volts can be obtained with the volt-age regulator knob turned toward maximum; 440 volts canbe obtained with the voltage regulator knob is turned down;and 416 volts can be obtained with the voltage regulatorknob is at the lowest setting.

Single Phase: 277V, 254V, or 240VThis setting can provide single phase power at 277, 254, or240 volts. After hooking up the hard wires to the lugs asshown in Figure 24, 277 volts can be obtained with the volt-age regulator knob turned toward maximum; 254 volts canbe obtained with the voltage regulator knob is turned down;and 240 volts can be obtained with the voltage regulatorknob is at the lowest setting.

Figure 22. Hard Wire Hookup for Three Phase 480V, 440V, or416V

Figure 24. Hard Wire Hookup for Single Phase 277V, 254V,or 240V


Figure 21. Voltage Regulator Knob



Voltage Selector Switch- 3 Phase 240/139V PositionThe following are additional voltages available when the volt-age selector switch is in the ‘3 phase 240/139V’ position.

3 Phase, 240V, 220V, or 208 VoltThis setting can provide 3-phase power at 240, 220, or 208volts. After hooking up the hard wires to the lugs as shownin Figure 26, 240 volts can be obtained with the voltageregulator knob turned toward maximum; 220 volts can beobtained with the voltage regulator knob is turned down; and208 volts can be obtained with the voltage regulator knob isat the lowest setting.

Single Phase: 240V, 220V, or 208 VoltThis setting can provide single phase power at 240, 220, or208 volts. After hooking up the hard wires to the lugs asshown in Figure 27, 240 volts can be obtained with the volt-age regulator knob turned toward maximum; 220 volts canbe obtained with the voltage regulator knob is turned down;and 208 volts can be obtained with the voltage regulatorknob is at the lowest setting.

Single Phase: 139V, 127V, or 120VThis setting can provide single phase power at 139, 127, or120 volts. After hooking up the hard wires to the lugs asshown in Figure 28, 139 volts can be obtained with the volt-age regulator knob turned toward maximum; 127 volts canbe obtained with the voltage regulator knob is turned down;and 120 volts can be obtained with the voltage regulatorknob is at the lowest setting.

Figure 25. Voltage Selector Switch 240/139V Three PhasePosition

Figure 26. Hard Wire Hookup for Three Phase 240V, 220V, or208V





Voltage Selector Switch- Single Phase 240/120VPositionThe following are additional voltages available when the volt-age selector switch is in the ‘single phase 240/120V’ posi-tion.

Single Phase, 240 VoltThis setting can provide single phase power at 240 volts.After hooking up the hard wires to the lugs as shown inFigure 30, 240 volts can be obtained with the voltage regula-tor knob turned to fine tune.

Single Phase: 120 VoltThis setting can provide single phase power at 120 volts.After hooking up the hard wires to the lugs as shown inFigure 31, 120 volts can be obtained with the voltage regula-tor knob turned to fine tune.

Figure 29. Voltage Selector Switch 240/120V Single PhasePosition

Figure 30. Hard Wire Hookup for Single Phase 240 volt

Figure 31. Hard Wire Hookup for Single Phase, 120 volt



Outdoor Installation

Install the generator in a location where it will not be exposedto rain or sunshine. Make sure the generator is on securelevel ground so it cannot slide or shift around. Also installthe generator so the exhaust will not be discharged in thedirection of nearby homes.

The installation site must be relatively free from moistureand dust. All electrical equipment should be protected fromexcessive moisture. Failure to do will result in deteriorationof the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasivematerials have a tendency to cause excessive wear to theengine and alternator parts.

CAUTION :CAUTION :CAUTION :CAUTION :CAUTION :Pay close attention to ventilation whenoperating the generator inside tunnels andcaves. The engine exhaust containsnoxious elements. Engine exhaust mustbe routed to a ventilated area.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.Whenever an engine is installed indoors the exhaust fumesmust be vented to the outside. The engine should be installedat least two feet from any outside wall. Using an exhaustpipe which is too long or too small can cause excessiveback pressure which will cause the engine to heatexcessively and possibly burn the valves.

CAUTION CAUTION CAUTION CAUTION CAUTION :An electric shock may happen whenvibrators are used. Pay close attention tohandling when operating vibrators andalways use rubber boots and gloves toinsulate the body from electrical shock.

Generator Grounding

To guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.

Article 250 (Grounding) of the National Electrical Code (NEC)provides guide lines for proper grounding and specifies thatthe cable ground shall be connected to the grounding systemof the building as close to the point of cable entry aspractical.

NEC articles 250-64(b) and 250-66 set the followinggrounding requirements:

1. Use one of the following wire types to connect thegenerator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 31) connect theground cable between the lock washer and the nut onthe generator and tighten the nut fully. Connect the otherend of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth groundrod should be buried a minimum of 8 ft. into the ground.

DCA-40SSI — INSTALLATION

NOTEWhen connecting the generator to any buildingselectrical system ALWAYS consult with a licensedelectrician.


Figure 31. Typical Generator Grounding Application

DCA-40SSI — INSTALLATION


General Inspection Prior to Operation

The DCA-40SSI generator has been thoroughly inspectedand accepted prior to shipment from the factory. However,be sure to check for damaged parts or components, or loosenuts and bolts, which could have occurred in transit.

Extension Cable

When electric power is to be provided to various tools orloads at some distance from the generator, extensioncords are normally used. Cables should be sized to allowfor distance in length and amperage so that the voltagedrop between the generator and point of use (load) is heldto a minimum. Use the Cable Selection Guide (Table 11 )as a guide for selecting proper cable size.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 110 amp,main circuit breaker is provided to protect the UNV outputterminals from overload. In addition two single-pole, 20 ampGFCI circuit breakers are provided to protect the GFCIreceptacles from overload. Three 50 amp load circuit breakershave also been provided to protect the load side of thegenerator from overload. Make sure to switch ALL circuitbreakers to the "OFF" position prior to starting the engine.

DCA-40SSI — PRE-SETUP

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NOTE


Lubrication Oil

Fill the engine crankcase with lubricating oil through the fillerhole, but do not overfill. Make sure the generator is level.With the dipstick inserted all the way, but without being screwinto the filler hole, verify that the oil level is maintainedbetween the two notches (Figure 32) on the dipstick. SeeTable 12 for proper selection of engine oil.


Figure 32. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil isclean and viscous. If the oil is not clean, drain the oil byremoving the oil drain plug, and refill with the specified amountof oil as outlined in the Isuzu Engine Owner's Manual.

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Fuel

Fill the fuel tank with clean and fresh diesel fuel. DO NOTfill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishingfuel. Refer to the fuel tank capacity listed on page 23Specification Table 7.

The fuel tank cap must be closed tightly after filling. Handlefuel in a safety container. If the container does not have aspout, use a funnel. Wipe up any spilled fuel immediately.

CAUTION :CAUTION :CAUTION :CAUTION :CAUTION :Never fill the fuel tank while the engine isrunning or in the dark. Gasoline spillageon a hot engine can cause a fire orexplosion. If gasoline spillage occurs,wipe up the spilled gasoline completely

to prevent fire hazards.

Coolant

Use only drinkable tap water. If hard water or water withmany impurities is used, the inside of the engine and radiatormay become coated with deposits and cooling efficiencywill be reduced. See maintenance section on page 52 and53 on instructions to flush out radiator.

An anticorrosion additive added to the water will help preventdeposits and corrosion in the cooling system.



Day-to-day addition of coolant is done from the reserve tank.When adding coolant to the radiator, DO NOT remove theradiator cap until the unit has completely cooled. See Table13. for engine, radiator, and reserve tank coolant capacities.Make sure the coolant level in the reserve tank is alwaysbetween the "H" and the "L" markings.

CAUTION :CAUTION :CAUTION :CAUTION :CAUTION :When adding coolant or antifreeze to theradiator, do not remove the radiator capuntil the unit has completely cooled.

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Operation in Freezing WeatherWhen operating in freezing weather, be certain the properamount of antifreeze (Table 14) has been added.

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NOTE

Cleaning the Outer RadiatorThe engine may overheat if the radiator fins becomeoverloaded with dust or debris. Periodically clean the radiatorfins with compressed air. Cleaning inside the radiator isdangerous, so clean only with the engine turned off and thebattery disconnected.

Air CleanerPeriodic cleaning/replacement is necessary. Inspect it inaccordance with the Isuzu Engine Owner's Manual.

Fan Belt TensionA slack fan belt may contribute to overheating, or toinsufficient charging of the battery. Inspect the fan belt fordamage and wear and adjust it in accordance with the IsuzuEngine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15mm (Figure 33) when depressed with the thumb as shownbelow. Never place hands near the belts or fan while thegenerator is running.

Figure 33. Fan Belt Tension

Never place hands near the belts or fanwhile the generator set is running.

CAUTION :CAUTION :CAUTION :CAUTION :CAUTION :

Adjusting Fan BeltIf the fan belt does not have the 10 to 15 mm defectionfollow the procedure below to adjust:Loosen the alternator adjusting plate and alternator moundingbolt.Pivot the alternator at the mounting bolt toward the engineleft or right until the belt reflects the proper tension.Tighten the mounting bolt and the adjusting bolt.



Battery Cable InstallationALWAYS be sure the battery cables (Figure 34) are properlyconnected to the battery terminals as shown below. The REDcable is connected to the positive terminal of the battery,and the BLACK cable is connected to the negative terminalof the battery.


When connecting battery do the following:

1. DO NOT connect the battery cables to the batteryterminals when the key is in the ignition and is set in'START' mode. ALWAYS remove the key from theignition and the ignition switch is in the OFF positionwhen connecting the battery.

2. Place a small amount of grease around both batteryterminals. This will ensure a good connection and willhelp prevent corrosion around the battery terminals.


Inadequate battery connections maycause poor starting of the generator, andcreate other malfunctions.

WiringInspect the entire generator for bad or worn electrical wiringor connections. If any wiring or connections are exposed(insulation missing) replace wiring immediately.

Piping and Hose ConnectionInspect all piping, oil hose, and fuel hose connections forwear and tightness. Tighten all hose clamps and check hosesfor leaks.

If any hose (fuel or oil) lines are defective replace themimmediately.Figure 34. Battery Connections

If the battery cable is connectedincorrectly, damage to the generator willoccur. Pay close attention to the polarityof the battery when connecting thebattery.

BatteryThis unit is of negative ground. DO NOT connect in reverse.Always maintain battery fluid level between the specifiedmarks. Battery life will be shortened, if the fluid level is notproperly maintained. Add only distilled water whenreplenishment is necessary. DO NOT over fill.

The battery is sufficiently charged if the specific gravity ofthe battery fluid is 1.28 (at 68° F). If the specific gravityshould fall to 1.245 or lower, it indicates that the battery isdead and needs to be recharged or replaced.

Check to see whether the battery cables are loose. Poorcontact may result in poor starting or malfunctions. Alwayskeep the terminals firmly tightened. Coating the terminalswith a thin film of grease will help to inhibit corrosion.

AlternatorThe polarity of the alternator is negative grounding type.When an inverted circuit connection takes place, the circuitwill be in short circuit instantaneously resulting the alternatorfailure.

Do not put water directly on the alternator. Entry of waterinto the alternator leads an electrolyte corrosion causing analternator failure.

Before charging the battery with an external electric source,be sure to disconnect the battery cables.


DCA-40SSI — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generatorand equipment to insure the wattage, amperage andfrequency requirements are satisfactorily supplied by thegenerator for operating the equipment.

Generally, the wattage listed on the nameplate of theequipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, asthe wattage is influenced by the efficiency, power factor andstarting system of the equipment.

Motors and motor-driven equipment drawmuch greater current for starting thanduring operation.

An inadequate size connecting cable which cannot carrythe required load can cause a voltage drop which can burnout the appliance or tool and overheat the cable.

When connecting a resistance load such as anincandescent lamp or electric heater, a capacity of upto the generating set’s rated output (kW) can be used.

When connecting a fluorescent or mercury lamp, acapacity of up to the generating set’s rated output (kW)multiplied by 0.6 can be used.

When connecting an electric drill or other power tools,pay close attention to the required starting currentcapacity.

If wattage is not available on the equipment, approximatewattage may be determined by multiplying the nameplatevoltage by the nameplate amperage for three-phase:WATTS =1.732 x VOLTAGE x AMPERAGE

daoLyBrotcaFrewoP.51elbaT

daoLfOepyT rotcaFrewoP

srotomnoitcudniesahp-elgniS 57.0-4.0

tnecsednacni,sretaehcirtcelEspmal 0.1

spmalyrucrem,spmaltnecseroulF 9.0-4.0

noitacinummoc,secivedcinortcelEtnempiuqe 0.1

slootrewopnommoC 8.0

NOTEIf wattage is not given on theequipment's name plate, approximatewattage may be determined bymultiplying nameplate voltage by thenameplate amperage.WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 1.0. See Table 15.below when connecting loads.

Before connecting this generator to anybuilding’s electrical system, a licensedelectrician must install an isolation(transfer) switch. Serious injury or deathmay result without this transfer switch.

CAUTION:

Three Phase LoadWhen calculating the power requirements for 3-phase poweruse the following equation:


NOTEIf output (kVA) is not given on theequipment nameplate, approximateoutput may be determined bymultiplying voltage by amperage by


WARNING:WARNING:WARNING:WARNING:WARNING:

Before Starting

Engine

1. Check the lubricating oil level prior to starting the engine.Make sure the generator is level. The oil level must bemaintained between two notches on the dipstick.

2. When there is not enough lubricating oil, fill the crankcasewith high grade motor oil. Use a high quality detergentoil classified CC or higher (See Table 12 on page 43).

3. Check the coolant level in the radiator and subtank.Replenish with antifreeze as necessary. Always maintainthe coolant level between the FULL and LOW markingson the coolant container. Be sure that the radiator cap isfastened securely.

4. Check the fuel level on the fuel gauge. If fuel is low, fillthe fuel tank with clean fresh unleaded automotive diesel.If diesel spillage occurs, completely wipe up the spilledfuel immediately.

Before Starting

Generator and Control PanelCAUTION:

1. Be sure to disconnect theelectrical load and switch the main, load and G.F.C.I.circuit breakers (Figure 35) to the “OFF” position prior tostarting the engine.

NEVER start the engine with themain, GFCI or load circuit breakersin the ON position.

The engine's exhaust contains harmfulemissions. ALWAYS ventilate theexhaust when operating inside tunnels,excavations or buildings. Direct exhaustaway from nearby personnel.

Figure 35. Main, GFCI andLoad Circuit Breakers

DCA-40SSI — GENERATOR START-UP PROCEDURE

2. Connect the load to the UNV terminals as shown inFigure 36. These terminals can be found on the outputterminal panel, (see page 33 Figure 12). To gain accessto the output terminals lift the UNV cover. Tightenterminal nuts securely to prevent load wires from slippingout.

Figure 36. UNV Terminal Lugs (Load)

NEGATIVE

POSTIVE

BATTERY

3. Connect the negative battery cable (BLACK) to thenegative post on the battery (Figure 37).

Figure 37. Battery Connections


9. The generator's frequency meter (Figure 43) displaysthe 60 cycle output frequency in HERTZ.

Figure 44. Voltage Meter (Volts)

10. The generator's voltage meter (Figure 44) displays the120 VAC in VOLTS. If the voltage is not within thespecified frequency tolerance, use the voltageadjustment control knob (Figure 45) to increase ordecrease the desired voltage.

Figure 39. Voltage Selection Switch

Figure 45. Voltage Adjust Control Knob

4. Close all engine enclosure doors (Figure 38).

Figure 38. Engine Enclosure Doors


5. Check the voltage selection switch (Figure 39) isat the desired voltage.

6. Turn and push the engine throttle control lever(Figure 40) to ‘Low’.

7. Preheat the engine by turning the ignition key tothe left. Once the preheat lamp luminates, turn thekey to the farthest right to start the engine. Oncethe engine start to crank, release the key to‘operation’ (Figure 41).

8. Once the engine is warm and the engine isrunning properly, pull and turn the engine throttlecontrol lever to ‘High’ (Figure 42).

Figure 40. Engine Throttle Control Lever (low)

Figure 41. Starter Switch

Figure 42. Engine Speed Switch (high)

Figure 43. Frequency Meter (Hz)


A

0

40

60

75

20

Figure 46. Ammeter (No Load)

11. The ammeter (Figure 46) will indicate zero amps with noload applied. When a load is applied, this meter willindicate the amount of current that the load is drawingfrom the generator’s alternator.

Figure 49. Engine Tachometer


12. The engine oil pressure gauge (Figure 47) will indicatethe oil pressure (kg/ cm2) of the engine. Under normaloperating conditions the oil pressure is approximately25 psi.

13. The coolant temperature gauge (Figure 48) will indicatethe coolant temperature. Under normal operatingconditions the coolant temperature is between 165 and215 degrees Fahrenheit.

WATER TEMP

Figure 48. Coolant Temperature Gauge

Figure 47. Oil Pressure Gauge

14. The tachometer (Figure 49) will indicate the speed ofthe engine when the generator is operating. Under normaloperating conditions this speed is approximately 1800RPM’s.

16. Observe the generator's ammeter (Figure 51) and verifyit reads the anticipated amount of current with respectto the load. The ammeter will only display a currentreading if the load is in use.

17. The generator will run until manually stopped or anabnormal condition occurs.

Figure 50. Main and GFCI Circuit Breakers

Figure 51. Ammeter (Load)

A

0

40

60

75

20

15. Turn the MAIN, GFCI and LOAD circuit breakers totheir ON position (Figure 50).


1. To stop the engine in the event of an emergency, switchthe MAIN, GFCI and LOAD circuit breakers to ‘OFF’position.

2. Turn the starter switch key to ‘Stop’ position.

EMERGENCY STOPENGINE SHUTDOWNTo shutdown the generator, use the following procedure:

1. Switch both the MAIN, GFCI and LOAD circuit breakers(Figure 52) to the “OFF” position.

2. Turn and push the engine throttle control lever (Figure53) to the idle (low) position.

3. Let the engine cool by running it for 3-5 minutes with noload applied.

4. Turn the starter switch key to ‘Stop” position (Figure54).

5. Remove the load from the UNV terminal strip.

Figure 52. Main, GFCI and Load circuit breakers

Figure 53. Engine Throttle Control Lever

DCA-40SSI — GENERATOR SHUTDOWN PROCEDURE

Figure 54. Off/Manual Auto Switch


NOTE PAGE


DCA-40SSI — MAINTENANCE

General Inspection

Prior to each use, the generator should be cleaned andinspected for deficiencies. Check for loose, missing ordamaged nuts, bolts or other fasteners. Also check for fuel,oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean heavyduty paper element with kerosene, or foam element withliquid detergent and hot water. Wrap foam element in a clothand squeeze dry. For heavy duty paper element, wipeexcess kerosene with towel.

The air cleaner is equipped with an indicator. After the dirtyair cleaner has been replaced, press the dust indicator buttonto reset the indicator.

Fuel Addition

Add diesel fuel (the grade may vary according to seasonand locations). Always pour through the mesh filter.

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulatein the bottom of the tank. Occasionally remove the draincock and drain the contents. During cold weather, the moreempty volume inside the tank, the easier it is for water tocondense. This can be reduced by keeping the tank full asmuch as possible.

Air Removal

If air enters the fuel injection system of a diesel engine,starting becomes impossible. After running out of fuel, orafter disassembling the fuel system, bleed the systemaccording to the following procedure.

To restart after running out of fuel, turn the switch to the“ON” position for 15-30 seconds. Try again, if needed. Thisunit is equipped with an automatic air bleeding system.

Service Daily

If the engine is operating in very dusty or dry grassconditions, a clogged air cleaner will result. This can lead toa loss of power, excessive carbon buildup in the combustionchamber in high fuel consumption.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Removedust or water in the strainer cap and wash it in gasoline.Securely fasten the fuel strainer cap so that fuel will notleak. Check the fuel strainer every 200 hours of operation oronce a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when thefuel tank is filled. Insufficient oil may cause severe damageto the engine. Make sure the generator is level. The oil levelmust be between the two notches on the dipstick as shownin Figure 32, page 43.

Replacing Oil Filter

Detach the oil filter cartridge with a filter wrench.

Apply a film of oil to the gasket for the cartridge.

Screw in the cartridge by hand. When the gasket is incontact with the seal surface, tighten the cartridge oneor two more times by hand.

After the oil cartridge has been replaced, the engine oilwill drop slightly. Run the engine for a while and checkfor leaks before adding more oil if needed. Cleanexcessive oil from engine.

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 400hours or so.

Apply fuel oil thinly over the gasket and hand-tightenthe cartridge into position.

Vent any air.

Fuel Injection Nozzle

Use an injection nozzle tester to check the static injectionstarting pressure and the fuel spray conditions.

Abnormal fuel consumption will lead to a lowered outputand blackish exhaust smoke. The required injectionstarting pressure should be 14.7MPa (150kg/cm2,2130psi).




Allow engine to cool when flushing outradiator. Flushing the radiator while hot willdamage radiator.

Feed Pump Strainer Cleaning

The strainer is incorporated in the feed pump inlet side jointbolt. Clean the strainer with compressed air and rinse it inthe fuel oil.

Flushing Out Radiator and Replacing Coolant

Open both cocks located at the crankcase side and atthe lower part of the radiator and drain coolant. Openthe radiator cap while draining. Remove the overflowtank and drain.

Check hoses for softening and kinks. Check clamps forsigns of leakage.

Flush the radiator by running clean tap water throughradiator until signs of rust and dirt are removed. DONOT clean radiator core with any objects, such as ascrewdriver.

Tighten both cocks and replace the overflow tank.

Replace with coolant (see page 44, Table 14 for mixture).

Close radiator cap tightly.



Figure 55. Valve Adjustment

Valve Clearance Check

1. In order to bring No. 1 or No. 4 cylinder to top dead centerin the compression stroke, align the notched line on thecrank pulley with TDC mark on the timing gear casecover.

2. Do the adjustment on the circle marked valves in thebelow table where No. 1 cylinder is at the center in thecompression stroke.

3. After adjustment started from either piston top center,turn the crankshaft 360o to align the notched line withthe TDC mark to do the adjustment again on theremaining valve. See Table 16 and Figure 55 for valvearrangement.

Injection Timing Check and Adjustment

1. Bring No. cylinder to the top dead center on thecompression stroke.

2. Turn the crankshaft pulley clockwise (viewed at enginefront) and align the notched line on the crank pulley withthe TDC mark on the timing gear case cover.

3. Remove the timing check hole cover at the front ofinjection pump to check the alignment between thepointer “a” on the injection pump gear lock plate and theprojected area mark “b” on the timing gear case.

4. If “a” and “b” are in alignment, the timing is set correctly.If not, follow nos. 1-3 until the “a” and “b” are aligned.

5. Reversely turn the crankshaft pulley counterclockwiseviewed at the engine front about 30o crank angle.

6. Remove No. 1 injection pipe from the engine.

7. Remove the injection pump No. 1 delivery valve holder,delivery valve and spring and reinstall the delivery valveholder on the original place.

8. Delivery valve holder tightening torque:39~44Nm(29~33lbft.)

9. Slowly turn the crankshaft pulley clockwise and at thesame time continue to feed the fuel with pumping theFeed pump. When the fuel stop to flow out from No. 1delivery valve holder, stop pumping.

10. Observe and make sure which mark (injection startingangle line) on the timing gear case cover is aligning withthe notched line on the crank pulley.

11. The timing line shows the injection starting crank angleof the engine.

12. The injection starting crank angle should be at the 14o

timing mark.

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tnemegnarrAevlaV I E I E I E I E

pottasi1.oNnehWehtniretnecdaedekotsnoisserpmoc

X X X X

pottasi4.oNnehWehtniretnecdaedekortsnoisserpmoc

O O O O

NOTE:

Take necessary precautions to prevent dust andforeign particles in the pump interior when timingadjustments are made.


Generator Storage

For storage of the generator for over 30 days, the followingis required:

Fill the fuel tank completely.

Completely drain the oil from the crankcase and refillwith fresh oil.

ECNANETNIAM/NOITCEPSNI srH01YLIAD srH052 srH005 srH0001

ENIGNE

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR 1 X

retliFriAnaelC X

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC 2 X

noitcetorPtnalooCkcehCdnarotaidaRnaelCleveL

X

elzzoNnoitcejnIleuFtseT X

tnemelEretliFriAecalpeR X

spmalCdnasesoHllakcehC X

ecnaraelCevlaVkcehC X

elzzoNnoitcejnIkcehC X X

knaTleuFfoedisnInaelC X

ROTARENEG smhoM3revOecnatsiseRnoitalusnIerusaeM X

*1 .ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

*2 .ylnoemittsrif,sruoH052taretlifleufecalpeR

Clean all external parts of the generator with a cloth.

Cover the generating set and store in a clean, dry place.



DCA-40SSI — ENGINE WIRING DIAGRAM


DCA-40SSI — GENERATOR WIRING DIAGRAM


NOTE PAGE


DCA-40SSI — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by properhandling and maintenance inspections, but in the event of abreakdown, use the tables shown for

diagnosis based on the Engine Troubleshooting (Table 1 7).If the problem cannot be remedied, consult our company'sbusiness office or service plant.

GNITOOHSELBUORTENIGNE.71ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.tratstonseodenignE

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

leuffoytisocsivhgihylevissecxE?erutarepmetwoltalioenignero .lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF?tungniniaterepip .tunnethgiT

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS?gniraebrorenilrednilyc,notsip .ecalperroriapeR

?rednilycmorfkaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR.redlohelzzon

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.nurtonseodretratS?gninoitcnuflamretratS .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC


DCA-40SSI — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.71ELBAT


.htoomstonsinoituloverenignE

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF?tungniniaterepip .tunnethgiT

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI?erusserp .tsujdA

rokcutselzzonnoitcejnI?deggolc .ecalperroriapeR

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

sagtsuahxeeulbroetihwrehtiE.devresbosi

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP?kcuts .ecalperroriapeR


?noisserpmoctneicifeD .ecnaraelcpottsujdA

tsuahxeyargkradrokcalbrehtiE.devresbosisag

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.tuptuotneicifeD


otmeesstrapgnivoms'enignE?gnizieseb .ecalperroriapeR

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR.redlohelzzon


GNITOOHSELBUORTROTARENEG.81ELBAT


tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of abreakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table18) . If theproblem cannot be remedied, consult our company's business office or service plant.

DCA-40SSI — TROUBLESHOOTING (GENERATOR)


NOTE PAGE


How to read the marks and remarks used in this partsbook.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serialnumber range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that thecorresponding part is utilized only with this specific modelnumber or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, *, #,+, or %, belong to the same assembly or kit.

Note: If more than one of the same reference number islisted, the last one listed indicates newest (or latest)part available.

EXPLANATION OF CODE IN REMARKS COLUMN


DCA-40SSI W/ISUZU 4BG1 DIESEL ENGINE 1 TO 3 UNITS

DCA-40SSI — SUGGESTED SPARE PARTS

NOTEPart number on this Suggested SpareParts list may supercede/replace theP/N shown in the text pages of this

book.

Qty. P/N Description1 ......... 0601808811 ..............CIRCUIT BREAKER1 ......... 0601820671 ..............AUTOMATIC VOLTAGE REGULATOR1 ......... 0601840073 ..............RHEOSTAT VOLTAGE REGULATOR1 ......... 0601840121 ..............KNOB RHEOSTAT1 ......... M1310500403 ...........RADIATOR HOSE1 ......... M1310500303 ...........RADIATOR HOSE1 ......... 8941324900 ..............RADIATOR HOSE5 ......... 8943212191 ..............OIL FILTER5 ......... X132400240 .............FUEL FILTER5 ......... 0602046368 ..............AIR ELEMENT1 ......... 0602122272 ..............UNIT OIL PRESSURE1 ......... 0602123260 ..............UNIT WATER TEMPERATURE1 ......... 0601810245 ..............BULB, ALARM LAMP1 ......... 8970208220 ..............FAN BELT1 ......... 1823100080 ..............STARTER SWITCH3 ......... KEYISUZUF .............KEY, STARTER SWITCH


DCA-40SSI --- GENERATOR ASSY.GENERATOR ASSY.


NO. PART NO. ITEM QTY. REMARKS

DCA-40SSI --- GENERATOR ASSY.

GENERATOR ASSY.

1 8051000032 ROTOR ASSY. 11-1 FIELD ASSY. 11-2 8051070003 FAN 11-3 0105091025 HEX. HEAD BOLT ............................8 .......... REPLACES 00103100251-4 030210250 LOCK WASHER ...............................8 .......... REPLACES 00425100001-5 8041611004 COUPLING DISK 41-6 8041015003 BALANCING PLATE 11-7 0105091025 HEX. HEAD BOLT ............................6 .......... REPLACES 00103100251-8 0042610000 LOCK WASHER 61-9 8001026013 SET PLATE, RECTIFIER 11-10 0601821349 RECTIFIER ......................................2 .......... PT 36101-11 0601822601 SURGE ABSORBER .......................1 .......... ERZ-M14JK621A1-12 8001020004 INSULATOR WASHER 11-13 8001020504 INSULATOR WASHER 11-14 011008020 HEX. HEAD BOLT ............................4 .......... REPLACES 00101080201-15 0040080000 LOCK WASHER 41-16 0601000209 BALANCING WEIGHT KIT 11-17 0070806309 BEARING .........................................1 .......... 6309DU2 8051614003 COUPLING RING .............................1 .......... REPLACES M11634002033 8051653004 REAMER BOLT 14 012010030 HEX. HEAD BOLT ............................7 .......... REPLACES 00121100305 030210250 LOCK WASHER ...............................9 .......... REPLACES 00425100006 8051340503 STRATOR ASSY. 17 0845041904 GROMMET 28 8041315102 END BRACKET 19 8041350013 FIELD ASSY. EXCITER 110 0010308065 HEX. HEAD BOLT 411 0042608000 LOCK WASHER 412 031108160 PLAIN WASHER ..............................4 .......... REPLACES 004120800013 0010108025 HEX. HEAD BOLT 614 0040008000 LOCK WASHER 615 031108160 PLAIN WASHER ..............................6 .......... REPLACES 004120800016 060100003 WAVE WASHER ...............................1 .......... BWW630917 8041310014 COVER, BEARING 118 8041312004 GASKET, BEARING 119 8041331014 COVER, END BRACKET 120 0105050616 HEX. HEAD BOLT ............................8 .......... REPLACES 001710601221 8001333003 COVER, END BRACKET 122 0010106030 HEX. HEAD BOLT 223 0040006000 LOCK WASHER 224 952404470 PLAIN WASHER ..............................2 .......... REPLACES 004120600025 0105091025 HEX. HEAD BOLT ............................6 .......... REPLACES 001031002526 030210250 LOCK WASHER ...............................6 .......... REPLACES 004251000027 8051332003 COVER, FAN 128 0605000010 RUBBER SUSPENSION 229 0030012000 HEX. NUT 4

0040012000 LOCK WASHER 4


DCA-40SSI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.



DCA-40SSI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

1 8081812502 CONTROL BOX 12 0601801145 CURRENT TRANSFORMER, AMMETER ..... 3 ......... CT3.5MR 150/5A3 0027104010 MACHINE SCREW 64 0601823860 RELAY UNIT .................................................. 2 ......... MSA90135 0027104016 MACHINE SCREW 46 0601820671 AUTOMATIC VOLTAGE REGULATOR ............ 1 ......... NTA5A2D; REPLACES 06018206287 0027105012 MACHINE SCREW 48 0601820892 OVER CURRENT RELAY .............................. 1 ......... THK20KP; REPLACES 06018208539 0027104016 MACHINE SCREW 210 1825500732 EMERGENCY RELAY ................................... 1 ......... REPLACES 1825500730

& 060220040511 0027106016 MACHINE SCREW 412 0601823706 RELAY ........................................................... 1 ......... JH1A DC24V13 0027104016 MACHINE SCREW 214 0601806522 CURCUIT BREAKER .................................... 1 ......... XE100CS 100AT15 0021004060 MACHINE SCREW 2

0040004000 LOCK WASHER 2031104080 PLAIN WASHER ............................................ 2 ......... REPLACES 0041204000

16 M1923100004 SELECTOR SWITCH .................................... 1 ......... REPLACES 801015310417 0020004010 MACHINE SCREW ........................................ 4 ......... REPLACES 002110401018 8051839504 BRACKET, SELECTOR SWITCH 119 0021003010 MACHINE SCREW 420 0017106016 HEX. HEAD BOLT 2

020106050 HEX. NUT ...................................................... 2 ......... REPLACES 003000600021 3341822503 CONTROL PANEL 122 0601800460 FREQUENCY METER................................... 1 ......... PAK60 220V 45~65Hz23 0601800729 AC AMMETER .............................................. 1 ......... PSK60 0~75A 0~150A24 0601801040 CHG. OVER SW., AMMETER ....................... 1 ......... SL2VS27 0601810072 PILOT LAMP ................................................. 1 ......... LP132DC 220V

0601810261 BULB 128 0601840073 VOLTAGE REGULATOR ................................ 1 ......... RA20A2SE102BJ 2W 1KOHM29 0601840121 KNOB 130 3331824003 STOPPER, CONTROL PANEL 131 0027105016 MACHINE SCREW 2

0030005000 HEX. NUT 232 0805001304 SET SCREW 233 031108160 PLAIN WASHER ............................................ 2 ......... REPLACES 004120800034 020108060 HEX. NUT ...................................................... 2 ......... REPLACES 003000800035 0027105010 MACHINE SCREW 436 8051814304 COVER 137 0017106016 HEX. HEAD BOLT 1138 8081814604 SIDE PANEL 139 0017106016 HEX. HEAD BOLT 440 0017100025 HEX. HEAD BOLT 4


DCA-40SSI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.



NO. PART NO. ITEM QTY. REMARKSENGINE AND RADIATOR ASSY.

1 4BD1PD02 ENGINE .......................................... 1 .......... ISUZU 4BD1; REPLACES 06020000782 0602010800 RADIATOR ...................................... 1 .......... B9611100023 0602011303 RADIATOR NECK ........................... 1 .......... 40791113004 0602011102 HOSE .............................................. 1 .......... B96111119105 0602014062 HOSE BAND ................................... 2 .......... G0001001316 0602011000 RADIATOR CAP .............................. 1 .......... 7880K111007 0017106016 HEX.HEAD BOLT 48 3345123104 BRACKET, RADIATOR 29 011008020 HEX. HEAD BOLT ........................... 12 ........ REPLACES 001710802010 0602013086 RADIATOR HOSE 111 0602013186 RADIATOR HOSE 112 0602014000 HOSE BAND 213 0602014006 HOSE BAND 114 0602014071 HOSE BAND 115 0602040094 AIR CLEANER ................................ 1 .......... FWG068002

0602040197 ELEMENT, AIR CLEANER.............. 1 .......... P10487316 0602040690 DUST INDICATOR ........................... 1 .......... RBX002252; REPLACES 06204069017 0602040587 BAND, AIR CLEANER .................... 2 .......... AAH00821818 0017108020 HEX. HEAD BOLT 419 3342032103 HOSE, AIR CLEANER 120 0605515011 HSOE BAND 121 0605515028 HOSE BAND 122 0602041107 ELEMENT, OIL FILTER .................. 1 .......... 187810220123 0602042108 ELEMENT, FUEL FILTER ............... 1 .......... 587810050024 3345112503 ENGINE FOOT 125 3345112403 ENGINE FOOT 126 0041210000 PLAIN WSAHER 827 0040010000 LOCK WASHER 828 0105091025 HEX. HEAD BOLT ........................... 8 .......... REPLACES 001071002529 0605000009 RUBBER SUSPENSION 230 0040012000 LOCK WASHER 431 0039312000 HEX. NUT ....................................... 4 .......... REPLACES 003011200032 1819001931 ENGINE STOPPER ........................ 1 .......... REPLACES 060221080333 0027106016 MACHINE SCREW 334 3342054104 DRAIN JOINT 135 0805013704 PACKING, OIL PAN SIDE 136 0805014204 PACKING 137 3362054104 JOINT BOLT 138 3342051104 DRAIN JOINT 139 0802024004 PACKING 1



ENGINE AND RADIATOR ASSY.



NO. PART NO. ITEM QTY. REMARKSENGINE AND RADIATOR ASSY.

40 0802010204 PLUG 141 3342022104 DRAIN HOSE 142 0605515003 HOSE BAND 243 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 001710802044 020108060 HEX. NUT ....................................... 2 .......... REPLACES 003000800045 0845031303 RESERVE TANK 146 0802081104 CAP, RESERVE TANK 147 3342082304 BRACKET, RESERVE TANK 148 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 001710802049 011606025 HEX. HEAD BOLT ........................... 1 .......... REPLACES 001710602550 0199500950 HOSE 151 0199500175 HOSE 152 0193601000 HOSE 153 06055150013 HOSE BAND 454 0193900750 BREATHER HOSE 155 0605515030 HOSE BAND 256 0193100700 HOSE 157 0605515007 HOSE BAND 158 0193800750 HOSE 159 0605515019 HOSE BAND 160 3342220604 EARTH CABLE 1


ENGINE OPERATING PANEL ASSY.

DCA-40SSI --- ENGINE OPERATING PANEL ASSY.




NO. PART NO. ITEM QTY. REMARKS1 3342101003 OPERATING PANEL 12 7452142014 SLIDE BAR 13 0601840190 KNOB .............................................. 1 .......... REPLACES 08050129044 020108060 HEX. NUT ....................................... 1 .......... REPLACES 00360030005 7452140504 BRACKET, GOVERNOR ROD 16 020108060 HEX. NUT ....................................... 2 .......... REPLACES 00300080007 0605010503 SNAP PIN 18 0602100004 STARTER SWITCH ......................... 1 .......... 182310000809 9825300460 PREHEAT LAMP............................. 1 .......... REPLACES 060210200610 0602120054 TACHOMETER................................ 1 .......... 25000KX411011 0602120154 CABLE, TACHOMETER .................. 1 .......... 6211000KA6710 L=115012 0602122060 OIL PRESSURE GAUGE ................ 1 .......... 42000KX141013 0602122200 UNIT, OIL PRESSURE.................... 1 .......... 53000AC010114 0131300000 STREET SOCKET 115 0602123061 WATER TEMPERATURE GAUGE ... 1 .......... 40000KX091016 0602123201 UNIT, WATER TEMPERATURE ....... 1 .......... 54100KV020017 0602121052 CHARGINE AMMETER .................. 1 .......... 43000KV030018 0602103091 ALARM LAMP ................................. 2 .......... REPLACES 0602103090

0601810214 BULB............................................... 2 .......... REPLACES 060181024419 0601830420 SWITCH, LAMP CHECK 120 0601810120 PANEL LIGHT ................................. 1 .......... DL31000

0601810201 BULB 121 0040520000 TOOTHED LOCK WASHER 122 0601830710 SWITCH, PANEL LIGHT 123 011008040 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0010008040

0040008000 LOCK WASHER 2031108160 PLAIN WASHER ............................. 2 .......... REPLACES 0041208000

24 0017108020 HEX. HEAD BOLT 225 8055312103 SUPPORT LEG 126 0017110025 HEX. HEAD BOLT 227 011208025 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108025

020108060 HEX. NUT ....................................... 2 .......... REPLACES 0030008000




NO. PART NO. ITEM QTY. REMARKS28 3342183004 LINK, GOVERNOR ROD 129 0105091025 HEX. HEAD BOLT ........................... 1 .......... REPLACES 001001002530 031110160 PLAIN WASHER ............................. 2 .......... REPLACES 004121000031 020310080 HEX. NUT ....................................... 1 .......... REPLACES 003001000032 3342182014 GOVERNOR ROD 133 3342152114 GOVERNOR ROD 134 0602180106 BALL JOINT 235 020108060 HEX. NUT ....................................... 2 .......... REPLACES 003000800036 0602180108 BALL JOINT 137 020106050 HEX. NUT ....................................... 3 .......... REPLACES 003000600038 952404470 PLAIN WASHER ............................. 1 .......... REPLACES 004160600039 8111860303 SET BOARD, OUTPUT TERMINAL 140 0801831704A OUTPUT TERMINAL ....................... 5 .......... REPLACES 080183170441 012210020 HEX. HEAD BOLT ........................... 5 .......... REPLACES 080183180442 0039310000 HEX. NUT 1043 0040010000 LOCK WASHER 1544 0041410000 PLAIN WASHER 2045 011208030 HEX .HEAD BOLT .......................... 5 .......... REPLACES 001710803046 8051865904 COVER, OUTPUT TERMINAL 147 0605010051 HINGE 248 0027103016 MACHINE SCREW 12

0207003000 HEX. NUT 649 0017106016 HEX. HEAD BOLT 250 0601811034 RECEPTACLE ................................. 3 .......... CS6369 250V 50A51 0601811030 RECEPTACLE ................................. 2 .......... 5-20R 125V 20A x 252 0027103010 MACHINE SCREW 10

0207003000 HEX. NUT ....................................... 10 ........ REPLACES 003000300058413 PLAIN WASHER ............................. 10 ........ REPLACES 0041203000

53 0601805306 CURCUIT BREAKER ...................... 2 .......... KM51 265V 40A54 0601805840 CIRCUIT BREAKER ....................... 2 .......... KM52 265V 50A55 8081816303 BRACKET, CIRCUIT BREAKER 1

0223300200 RUBBER SHEET 156 0017106016 HEX. HEAD BOLT 257 8085182004 RUBBER COVER 158 8085183004 SET FRAME, RUBBER COVER 159 011206020 HEX. HEAD BOLT ........................... 6 .......... REPLACES 001710602060 8051865703 COVER, RECEPTACLE 161 012212045 HEX. HEAD BOLT ........................... 2 .......... REPLACES 001001204562 031112230 PLAIN WASHER ............................. 4 .......... REPLACES 004121200063 0805009804 RUBBER WASHER ......................... 2 .......... REPLACES 080500980464 0030012000 HEX. NUT 265 0601820015 RECTIFIER 466 0601802133 FUSE, 5A 1


DCA-40SSI --- BATTERY ASSY.

BATTERY ASSY.



DCA-40SSI --- BATTERY ASSY.

BATTERY ASSY.

1 0168409541 BATTERY ........................................ 2 ........... 95E41R2 0805003904 BATTERY SHEET 23 0805004004 BATTERY BAND 24 3802252004 BATTERY BOLT 45 031108160 PLAIN WASHER ............................. 4 .......... REPLACES 00412080006 0040008000 LOCK WASHER 47 0037808000 WING NUT 48 0215260050 BATTERY CABLE 19 0211160160 BATTERY CABLE 110 0215860045 BATTERY CABLE 111 0602220310 TERMINAL ASSY. (+) ..................... 2 ........... NO.9P

0037808000 WING NUT ...................................... 2 ........... REPLACES 020800800012 0602220311 TERMINAL ASSY. (-) ...................... 2 ........... NO. 9N

0027808000 WING NUT ...................................... 2 ........... REPLACES 0208008000


DCA-40SSI --- MUFFLER ASSY.

MUFFLER ASSY.



DCA-40SSI --- MUFFLER ASSY.

MUFFLER ASSY.

1 3342350103 EXHAUST PIPE 12 1141450690 GASKET ......................................... 1 .......... REPLACES 06023200003 0602323002 HEX. NUT ....................................... 6 .......... 90911031004 3342311102 MUFFLER 15 3342359104 MUFFLER SHEET 16 011208025 HEX. HEAD BOLT ........................... 2 .......... REPLACES 00171080257 012210020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 00171100208 3342356104 GASKET 19 011208035 HEX. HEAD BOLT ........................... 4 .......... REPLACES 001710803510 031108160 PLAIN WASHER ............................. 4 .......... REPLACES 004120800011 020108060 LOCK WASHER .............................. 4 .......... REPLACES 003000800012 3342354104 COVER 113 3342354004 COVER 114 3342328104 PIPE CLAMPER 115 031108160 PLAIN WASHER ............................. 2 .......... REPLACES 004120800016 020108060 HEX. NUT ....................................... 4 .......... REPLACES 003000800017 3342359004 COVER SHEET 218 011208025 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108025


DCA-40SSI --- FUEL TANK ASSY.

FUEL TANK ASSY.



DCA-40SSI --- FUEL TANK ASSY.

FUEL TANK ASSY.

1 3345510703 FUEL TANK 11-1 0810105004 CAP, FUEL TANK 11-2 0810105400 FUEL FILTER 11-3 0193100255 FUEL GAUGE HOSE 11-4 0605515079 HOSE BAND 22 3345523504 TANK BAND 23 0805003414 PAD, TANK BAND 44 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 00171080205 020108060 HEX .NUT ....................................... 2 .......... REPLACES 02070080006 020108060 HEX. NUT ....................................... 2 .......... REPLACES 00300080007 3805522004 TANK SHEET 48 0131906000 CAP 19 0191300670 SUCTION HOSE 110 0191300630 RETURN HOSE 111 0605515014 HOSE BAND 412 0845032204 DRAIN JOINT 113 0150000018 O RING 114 0802011104 PLUG 1


ENCLOSURE ASSY.

DCA-40SSI --- ENCLOSURE ASSY.


NO. PART NO. ITEM QTY. REMARKSENCLOSURE ASSY.


1 8055111102 BASE 12 3345116214 FLOOR PANEL 13 011008020 HEX. HEAD BOLT ........................... 10 ........ REPLACES 00171080204 3345116504 COVER 15 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 00171080206 3345121302 FRONT FRAME 1

3345109103 LINING 17 011008020 HEX. HEAD BOLT ........................... 6 .......... REPLACES 00171080208 3345122604 BRACKET, RADIATOR NECK 19 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 001710802010 3345125503 COVER, FRONT FRAME 1

3345109204 LINING 111 011008020 HEX. HEAD BOLT ........................... 16 ........ REPLACES 001710802012 3345125403 COVER, FRONT FRAME 113 011008020 HEX. HEAD BOLT ........................... 10 ........ REPLACES 001710802014 3385155104 COVER 215 011206020 HEX. HEAD BOLT ........................... 8 .......... REPLACES 001710602016 3345125204 COVER, FRONT FRAME 117 011008020 HEX .HEAD BOLT .......................... 6 .......... REPLACES 001710802018 3345132113 CENTER FRAME 119 3345132213 CENTER FRAME 120 012210040 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010014040

020114110 HEX. NUT ....................................... 8 .......... REPLACES 0030014000030214350 LOCK WASHER .............................. 8 .......... REPLACES 0040014000031114260 PLAIN WASHER ............................. 8 .......... REPLACES 0041214000

21 012012030 HEX .HEAD BOLT .......................... 10 ........ REPLACES 00100120300040012000 LOCK WASHER 10031112230 PLAIN WASHER ............................. 10 ........ REPLACES 0041212000

22 3345141222 REAR FRAME 13345109303 LINING 1

23 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 001710802024 3345155113 COVER, REAR FRAME 1

3345109413 LINING 125 0010008050 HEX. HEAD BOLT 8


26 3345143313 DOOR, REAR FRAME 127 3805147104 WINDOW PLATE 128 0021006020 MACHINE SCREW 6

020106050 HEX. NUT ....................................... 6 .......... REPLACES 00300060000040006000 LOCK WASHER 6


ENCLOSURE ASSY.



ENCLOSURE ASSY.


NO. PART NO. ITEM QTY. REMARKS952404470 PLAIN WASHER ............................. 6 .......... REPLACES 0041206000

29 0845028303 HINGE 230 011208025 HEX. HEAD BOLT ........................... 4 .......... REPLACES 001710802531 3345161212 ROOF PANEL 1

3345109503 LINING 132 011008020 HEX .HEAD BOLT .......................... 16 ........ REPLACES 001710802033 3345165104 GUIDE PANEL, AIR 2

3345109604 LINING 234 011008020 HEX. HEAD BOLT ........................... 8 .......... REPLACES 001710802035 8055181102 SPLASHER PANEL 1

3345105314 LINING 136 0010008055 HEX. HEAD BOLT 6


37 3345124013 SIDE DOOR 13345109704 LINING 1

38 3345124113 SIDE DOOR 13345109804 LINING 1

39 3345175104 GUIDE PANEL, AIR 23345105104 LINING 2

40 011008020 HEX. HEAD BOLT ........................... 12 ........ REPLACES 001710802041 3345171813 SIDE DOOR 1

3345109904 LINING 142 3345175004 GUIDE PANEL, AIR 1

3345105204 LINING 143 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 001710802044 3345171923 SIDE DOOR 1

3345105014 LINING 145 0845028203 HINGE 446 0845028303 HINGE 447 011208025 HEX. HEAD BOLT ........................... 16 ........ REPLACES 001710802548 0601850097 RUBBER CUSHION 849 0845031504 CAP 1050 0600500090 EMBLEM......................................... 2 .......... REPLACES 636051000351 0021106020 MACHINE SCREW 452 B3561100003 STRIPE ........................................... 1 .......... REPLACES 334063010353 B3561100103 STRIPE, LEFT SIDE ...................... 1 .......... REPLACES 334063030354 3340630503 STRIPE, RIGHT SIDE 1



ENCLOSURE ASSY.




ENCLOSURE ASSY.

55 3340630904 STRIPE 256 B3561100403 STRIPE ........................................... 1 .......... REPLACES 334063110457 B3561100403 STRIPE ........................................... 1 .......... REPLACES 334063130458 B3561100204 STRIPE ........................................... 2 .......... REPLACES 334063070459 3345104104 RUBBER SEAL 260 3345104204 RUBBER SEAL 261 3345104304 RUBBER SEAL 362 3345104404 RUBBER SEAL 163 3345104514 RUBBER SEAL 164 3345104614 RUBBER SEAL 165 3345104714 RUBBER SEAL 166 3345104804 RUBBER SEAL 267 3345104904 RUBBER SEAL 268 0225100395 RUBBER SEAL 169 0220100395 RUBBER SEAL 170 0220200750 RUBBER SEAL 2


DCA-40SSI --- DECALS

DECAL ASSY.



DCA-40SSI --- DECALS

DECAL ASSY.

1 M1550000204 DECAL; NOTE ........................................................ 1 ...... M150000202 3340670112 DECAL; GENERATOR CONTROL .......................... 1 ...... S2358B3 3340670002 DECAL; ENGINE OPERATING .............................. 1 ...... S2361A4 8050670103 DECAL; AUXILIARY OUTPUT ............................... 1 ...... S33495 M1550000804 DECAL; NOTE ........................................................ 1 ...... M150000806 M9500000004 DECAL; OIL DRAIN PLUG ..................................... 1 ...... M90000007 M9500100004 DECAL; WATER ..................................................... 1 ...... M900100008 M9500300004 DECAL; - ................................................................ 1 ...... M900300009 M9500300104 DECAL; + ............................................................... 1 ...... M9003001010 M9500500004 DECAL; DIESEL FUEL .......................................... 1 ...... M9005000011 M9500500104 DECAL; FUEL DRAIN PLUG.................................. 1 ...... M9005001012 M9503000004 DECAL; WARNING ................................................. 2 ...... M9030000013 M9503000103 DECAL; WATER, OIL CHECK ................................ 1 ...... M9031000014 M9503100004 DECAL; WARNING ................................................. 1 ...... M9032000015 M9503200004 DECAL; WARNING ................................................. 1 ...... M9032000016 M9510100004 DECAL; CAUTION .................................................. 1 ...... M9101000017 M9510200002 DECAL; MQ ........................................................... 1 ...... M9102000018 M9520000004 DECAL; GROUND .................................................. 1 ...... M9200000019 M9520000104 DECAL; AMMETER CHANGE-OVER SWITCH ..... 1 ...... M9200001020 M9520000204 DECAL; VOLTMETER CHANGE-OVER SWITCH ..1 ...... M9200002021 M9520100004 DECAL; WARNING ................................................. 2 ...... M9201000022 M9520100204 DECAL; CAUTION .................................................. 1 ...... M92010020A23 M9520100304 DECAL; SAFETY INSTRUCTIONS ........................ 1 ...... M9201003024 M9520100404 DECAL; DANGER .................................................. 1 ...... M9201004025 M9520100503 DECAL; WARNING ................................................. 1 ...... M9201005026 M9520200003 DECAL; CONNECTION OF OUTPUT CABLE ....... 1 ...... M9202000027 M9520200104 DECAL; OVER CURRENT RELAY ......................... 1 ...... M92020010


CYLINDER HEAD COVER ASSY.

ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.


ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.

EA1013

CYLINDER HEAD COVER ASSY.

NO PART NO PART NAME QTY. REMARKS1 5111101680 CYLINDER HEAD ASSY. .................1 .......... INCL. ITEMS W/#2# 9117156070 VALVE SEAT, INTAKE 43# 9117118030 VALVE SEAT, EXHAUST 45# 1096000051 SEALING CUP, REAR FACE 15-1# 5112190150 SEALING CUP, EXHAUST MAN. 25-2# 1096000160 SEALING CUP, INLET SIDE FACE 45-3# 9111291280 SEALING CUP, LOWER FACE 25-4# 1096000160 SEALING CUP, TOP FAC 35-5# 50960000130 SEALING CUP, DRILLED PASS 46# 909600340 PLUG 47# 5117210010 VALVE GUIDE 89 9111296010 SEAL CUP 410 5093000650 ROCKER ARM STUD 311 1093000180 INJ. NOZZLE STUD 812 9092023100 PLUG, TOP FACE 113 9095714100 PACKING, COMMET 115 1125690150 VALVE GUIDE SEAL 816 9041108250 STUD, INL. MANIFOLD 217 9098301770 STUD, EXH. MANIFOLD 320 8941458390 GASKET, CYL. HEAD 122 8943674370 BOLT ................................................18 ........ REPLACES 894367438027 5111702672 CYL. HEAD COVER ASSY. .............1 .......... INCL. ITEMS W/&28& 9117510381 CAP, OIL FILLER 133 9111791050 WSAHER34 9111790300 PACKING, HEAD COVER 350 5111730160 PACKING, CYL. HEAD 151 9111750120 NUT 1


ISUZU 4BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.




NO PART NO PART NAME QTY. REMARKS1 8941303284 CYL. BLOCK ASSY ........................... 1 ........ INCL. ITEMS W/#2# 1112611180 LINING 43# 5112570011 DOWEL 14# 1090004691 BOLT 105# 9116110480 CAM., FRONT METAL 15-1# 9116130350 CAM., REAR AND CENTER 26# 1096000520 CEALING CUP, FRONT AND REAR 26-1# 5112190140 SEALING CUP, CYL. BLOCK 16-2# 1096000121 SEALING CUP, TAPPET D=32 28 9098600190 PLUG, CAMSHAFT PLATE 19 8941480790 DOWEL 210 1096050681 PLUG, HEADLESS PT 1/2 211 9992055170 OIL PLUG, GALLERY 111-1 5096050180 PLUG 712 9992023140 OIL PLUG, GALLERY 113 9095720140 PACKING 114 1097400780 STRAIGHT PIN, GEAR CASE 115-1 9081510180 STRAIGHT PIN, FLYWHEEL HSG. 218 8941075600 INJ. PUMP NIPPLE 119 5112240040 BUSHING, OIL PUMP DRIVE SHAFT120 5112901450 COVER, TAPPET CHAMBER 121 8943673680 PACKING, CYL. BLOCK COVER 222 8941075662 BOLT 222-1 8944299951 BOLT 223 9095720080 PACKING, COMET 427 1096253620 SEAL, REAR OIL CRANK 130 5111290030 SEALING CUP, LEVEL GAUGE 136 8941745290 COVER, OIL DRAIN 137 8943210180 PACKING, COVER 138 0500408180 BOLT 243 1093000530 STUD, ENGINE FOOT 149 5096800110 WATER DRAIN COCK 153 9099135050 PIPE 154 5097070041 DRAIN PIPE CLIP 156 5117401200 AIR BREATHER ASSY. 157 9091104080 NUT 259 9091505080 LOCK WASHER 260 9091645080 PLAIN WASHER 261 8944338700 BREATHER HOSE 162 8941625680 CLIP .................................................. 2 ........ REPLACES 109707134066 9097130740 OUOE 169 5097040331 CLIP 1



70 0500408160 BOLT 171 9091606080 PLAIN WASHER 180 8941405811 OIL FILLER ASSY. 181 1117500120 OIL FILLER CAP 182 9091104080 NUT 183 9091505080 LOCK WASHER 185 9099129760 HOSE 186 9099155531 CLIP 292 8970233390 VALVE RELIEF ASSY. 193 5096230350 PACKING 1

NO PART NO PART NAME QTY. REMARKSCYLINDER BLOCK ASSY.


ISUZU 4BD1 — TIMING GEAR ASSY.

TIMING GEAR ASSY.


ISUZU 4BD1 — TIMING GEAR ASSY.

TIMING GEAR ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 5113110113 CASE 12 9081510180 STRAIGHT PIN 13 1113120140 PACKING 14 0500408450 BOLT ............................................................... 6 .......... REPLACES 05004082006 1113210790 COVER 17 8943632690 PACKING 18 1096253190 SEAL 19 9113276020 POINTER 110 0500408250 BOLT 710 5090000841 BOLT 512 5113210090 COVER, GEAR CHECK 213 1112820130 GASKET 214 0500406140 BOLT 4


ISUZU 4BD1 — FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.


ISUZU 4BD1 — FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 8943213303 HOUSING 13 8943218380 PLUG, PICK UP HOSE 14 9992023160 DRAIN PLUG 15 9095714160 PACKING 19 9910664500 BOLT 89-1 0500408250 BOLT 711 9096510690 PLAIN WASHER 8


ISUZU 4BD1 — OIL PAN ASSY.

OIL PAN ASSY.



OIL PAN ASSY.

NO PART NO PART NAME QTY. REMARKS1 8941340361 OIL PAN ...................................... 1 ........ INCL. ITEMS W/#3# 9096620120 PLUG 13-1# 9992023160 PLUG, THERMO SWITCH 23-2# 9992023240 HEATER PLUG 14# 1096231830 O RING ....................................... 1 ........ REPLACES 10962305704-1# 9095714160 PACKING 24-2# 9095714240 PACKING 17 8943708360 OIL PAN PACKING ..................... 1 ........ UP TO MAR. 94

8943706660 OIL PAN PACKING ..................... 1 ........ APR. 94~9 0500408180 BOLT 2415 5117601500 GAUGE ASSY. 1



OIL PAN ASSY.



OIL PAN ASSY.

NO PART NO PART NAME QTY. REMARKS1 8941340361 OIL PAN ...................................... 1 ........ INCL. ITEMS W/#3# 9096620120 PLUG 13-1# 9992023160 PLUG, THERMO SWITCH 23-2# 9992023240 HEATER PLUG 14# 1096231830 O RING ....................................... 1 ........ REPLACES 10962305704-1# 9095714160 PACKING 24-2# 9095714240 PACKING 17 8943708360 OIL PAN PACKING ..................... 1 ........ UP TO MAR. 94

8943706660 OIL PAN PACKING ..................... 1 ........ APR. 94~9 0500408180 BOLT 2415 5117601500 GAUGE ASSY. 1


ISUZU 4BD1 — CRANKSHAFT. PISTON, FLYWHEEL ASSY.

CRANKSHAFT, PISTON, FLYWHEEL ASSY


ISUZU 4BD1 — CRANKSHAFT. PISTON, FLYWHEEL ASSY.

CRANKSHAFT, PISTON, FLYWHEEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 8941170322 CRANKSHAFT ASSY. ..................... 1 ......... INCL. ITEMS W/#1-1 8941474660 METAL KIT, 0.25 11-2 8941474670 METAL KIT, 0.50 11-3 8941474680 METAL KIT, 0.75 11-4 8941474690 METAL KIT, 1.00 12# 8941145652 METAL SET, THRUST 23 5121112111 PISTON SET 44 5121210050 RING SET, PISTON 45 9122116040 PISTON PIN 46 8941075750 SNAP RING 87 1122301041 CONNECTION ROD ASSY. ............. 4 ......... INCL. ITEMS W/&8& 1122510270 BUSHING, SMALL END 49& 1122350271 BOLT 811 9122716080 METAL SET, STD 411-1 9122736080 METAL SET, 0.25 411-2 9122746080 METAL SET, 0.50 411-3 9122756080 METAL SET, 0.75 411-4 9122766080 METAL SET, 1.00 414 5123101631 CRANSHAFT ASSY. ........................ 1 ......... INCL. ITEMS W/$15$ 9081612200 FLYWHEEL PIN 117 8941075970 FEATHER KEY 218 9125210430 CRANKSHAFT GEAR 120 8944493660 PULLEY 123 5123780020 NUT 124 5095030240 WASHER 125 9000901570 BALL BEARING 130 8970461810 FLYWHEEL ASSY. ........................... 1 ......... INCL. ITEMS W/%31% 9123336070 RING GEAR 133 5123360030 WASHER 134 5123340060 BOLT 6


ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY.

CAMSHAFT, IDLE GEAR, ROCKER ASSY.


ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY.

CAMSHAFT, IDLE GEAR, ROCKER ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 8944094120 CAMSHAFT 12 9125221471 GEAR 13 9080107200 FEATHER KEY 14 9116810150 THRUST PLATE 15 0500408250 BOLT 26 5090002360 BOLT 17 9098518503 WASHER 110 9125310300 IDLE GEAR SHAFT 111 9125238014 IDLE GEAR 113 5125350011 THRUST COLLAR 114 5090300381 BOLT 217 1125510501 INLET VALVE 418 1125520251 EXHAUST VALVE 419 5125610090 VALVE SPRING 821 1125630351 SPRING SEAT, LOWER 822 8941145760 SPRING SEAT, VALVE 823 5125650060 SPLIT COLLAR 1624 5125710032 TAPPET 825 1125750360 PUSH ROD 830 5126110310 ROCKER ARM ASSY. 831 9126160420 ADJUSTING SCREW 832 9091115080 NUT 833 8941295510 ROCKER ARM SHAFT 134 9126260050 ROCKER ARM PLUG 235 5126280120 BRACKET, FRONT 136 9126281050 BRACKET, INNER 437 1095803350 SPRING 338 1090005670 BOLT 639 9098514300 WASHER 640 9091800190 SNAP RING 141 5096230600 O RING PACKING 142 1094001160 NUT 343 9098514300 PLAIN WASHER 3


ISUZU 4BD1 — OIL AND FUEL FILTER ASSY.

OIL AND FUEL FILTER ASSY.


ISUZU 4BD1 — OIL AND FUEL FILTER ASSY.

OIL AND FUEL FILTER ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 5132002262 OIL FILTER ASSY. ............................. 1 ............. INCL. ITEMS W/#2# 1878102201 OIL FILTER ELEMENT KIT 110 1132191940 PACKING ............................................ 2 ............. UP TO MAR. 94

8943706700 PACKING ............................................ 2 ............. APR. 94~11 5132190261 SPACER 113 5090000071 BOLT 414 9091505100 LOCK WASHER 415 9091605100 PLAIN WASHER 450# 9132004193 FUEL FILTER ASSY. .......................... 1 ............. INCL. ITEMS W/&52#& 5878100500 FUEL FILTER ELEMENT KIT 160 0501510350 BOLT 2


ISUZU 4BD1 — OIL PIPING ASSY.

OIL PIPING ASSY.


ISUZU 4BD1 — OIL PIPING ASSY.

OIL PIPING ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 8941753012 OIL PUMP ASSY. 12 9099211880 PACKING 23 0501408450 BOLT 45 5133112561 FILTER PIPE ASSY. 16 1096234620 PACKING 27 0500408350 BOLT 27-1 0500408320 BOLT 210 8944284630 OIL INJECTION PIPE ASSY. 112 9095720100 PACKING 213 909840220 NUT 1


ISUZU 4BD1 — COOLING ASSY.

COOLING ASSY.


ISUZU 4BD1 — COOLING ASSY.

COOLING ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 5136101582 WATER PUMP ASSY. ...................... 1 ......... INCL. ITEMS W/#2# 8943763780 WATER PUMP KIT ........................... 1 ......... INCL. ITEMS W/%3& 5878101145 WATER PUMP REPAIR KIT ............. 1 ......... INCL. ITEMS W/&4& 5136310100 SHAFT 15& 5098000520 BALL BEARING 26& 5136320010 SPACER 17& 9099521030 SNAP RING 18& 9091801470 SNAP RING 19%& 8942366870 SEAL UNIT ASSY. 111%& 5136210110 IMPELLER 113& 5136420530 FAN 114% 5136120100 WATER PUMP COVER 115%& 5136130070 PACKING 117%& 9030908200 SCREW 319& 5136390020 DUST COVER 121& 5136340030 SPACER 123%& 5096250570 SEAL 127 5096050050 PLUG 128%& 9136140440 PACKING 129 0500410400 BOLT 1

0500410500 BOLT 25090300101 BOLT, WATER PUMP 2

31 5093610700 HOSE 132 5097040313 CLIP, D=38 1

1097040940 CLIP, D=36 135 9136600930 FAN ASSY. 137 5136630311 PULLEY 138 5136420581 SPACKER 140 5136710450 BELT 141 0500405600 BOLT 443 9098516490 PLAIN WASHER 448 5137700320 THERMOSTAT 149 8941760310 PACKING 150 5137160451 THERMOSTAT HOUSING 152 9096610050 THERMO PLUG 153 5096050050 PACKING .......................................... 1 ......... UP TO DEC. 93

9095713160 PACKING .......................................... 1 ......... DEC. 93~60 8943706740 PACKING .......................................... 1 ......... REPLACES 894321010062 5137130351 WATER PIPE 163 0500408250 BOLT 365 0501410250 BOLT 1

0500410400 BOLT 20501410350 BOLT 4

80 5112800111 WATER DUCT COVER ASSY. 181 8943210130 OIL COOLER PACKING 183 0500408200 BOLT 2

0500408250 BOLT 110500408450 BOLT 88942059861 BOLT 1


INTAKE AND EXHAUST ASSY.

ISUZU 4BD1 — INTAKE AND EXHAUST ASSY.


ISUZU 4BD1 — INTAKE AND EXHAUST ASSY.

INTAKE AND EXHAUST ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 5141112070 INTAKE MANIFOLD 13 8943632700 GASKET, INTAKE 14 9091104080 NUT 25 9091505080 LOCK WASHER 28 0500408250 BOLT 639 5096370281 PACKING 250 5141111160 INTAKE PIPE 150 5141111970 INTAKE PIPE 151 0501510300 BOLT 251-1 0500510300 BOLT 260 5141410360 EXHAUST MANIFOLD 161 5093020020 STUD, EXHAUST 362 5141450040 GASKET, EXHAUST 266 9091104080 NUT 567 9091505080 LOCK WASHER 569 8942059871 BOLT, L=75 2

0500408600 BOLT, FIXED 1


ISUZU 4BD1 — FUEL INJECTION ASSY.

FUEL INJECTION ASSY.


ISUZU 4BD1 — FUEL INJECTION ASSY.

FUEL INJECTION ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 5153001032 NOZZLE 43 5153150030 PACKING 45 9153390510 DUST COVER 48 9091104080 NUT 89 9091505080 LOCK WASHER 811 8944636740 PIPE, NO. 1 112 8944636750 PIPE, NO. 2 113 8944636760 PIPE, NO. 3 114 8944636770 PIPE, NO. 4 115 5154190131 CLIP ASSY., D6X2 ................. 3 ................... INCL. ITEMS W/#15-1# 9154196130 CLIP, A 315-2# 9154196140 CLIP, B 315-3# BOLT ...................................... 3 ................... NOT SOLD SEPARATELY FROM KIT16 5154190040 CLIP, INTAKE MANIFOLD 116-1 5154190051 CLIP, INTAKE MANIFOLD 116-2 0501406160 BOLT 118 5154112290 PIPE 120 5132600101 OVERFLOW VALVE ASSY. 127 5154115730 PIPE 129 5154118580 FILTER LEAK PIPE ASSY. 129-1 5154112231 EYE JOINT 130 5154116030 FILTER PIPE ASSY. 131 9099063141 BOLT 132 9095714080 PACKING, COMMET 233 9095720140 PACKING, FUEL PIPE 634 9099063251 BOLT 242 9095720140 PACKING 349 5097091030 CLIP A 249-1 5097091040 CLIP B 249-2 0500406250 CLIP BOLT 2


ISUZU 4BD1 — ENGINE FOOT ASSY.

ENGINE FOOT ASSY.


ISUZU 4BD1 — ENGINE FOOT ASSY.

ENGINE FOOT ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 9117712470 FOOT, FRONT RIGHT 12 9117712480 FOOT, FRONT LEFT 13 8943134650 BOLT 74 9091105100 NUT 15 9091505100 LOCK WASHER 117 5117770080 HANGER, FRONT 118 9117778050 HANGER, R. REAR 119 0500410200 BOLT 220 5197110620 BRACKET 122 0501408350 BOLT 1

0501408400 BOLT 127 0500410000 BOLT 127 0500410450 BOLT 1

5090300101 BOLT, L=75 128 8943717120 COVER, PULLEY 129 9091105080 NUT 130 9091505080 LOCK WASHER 131 9091606080 PLAIN WASHER 135 5136740320 PLATE 139 0500408400 BOLT 142 9091647080 PLAIN WASHER 1


ISUZU 4BD1 — ENGINE CONTROL ASSY.

ENGINE CONTROL ASSY.


ISUZU 4BD1 — ENGINE CONTROL ASSY.

ENGINE CONTROL ASSY.

NO. PART NO. PART NAME QTY. REMARKS2 5197890040 BRACKET 1


ISUZU 4BD1 — INJECTION PUMP ASSY.

INJECTION PUMP ASSY.


ISUZU 4BD1 — INJECTION PUMP ASSY.

INJECTION PUMP ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 8943440260 INJECTION PUMP ASSY. ......... 1 ................ INCL. ITEMS W/#3# 8943440280 GOVERNOR ASSY. 15# 8941327040 FEED PUMP ASSY. 114# 5125240650 GEAR 115# 1156192450 PLATE 116# 9096620070 BOLT 117# 5157810030 COUPLING 118# 8944575170 BOLT 619# 9884105020 NUT 120# 5156190480 LOCK WASHER 132 1113190090 PACKING 133 5090000841 BOLT 735 5197510150 BRACKET 136 0500410250 BOLT 238 9091105100 NUT 139 9091605100 PLAIN WASHER 140 9091505100 LOCK WASHER 1


ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY.

ELECTRICAL COMPONENTS ASSY.


ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY.

ELECTRICAL COMPONENTS ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 1811001910 STARTER ASSY 16 0500512280 BOLT 16 0500512350 BOLT 27 9091605120 PLAIN WASHER 18 9829315110 CABLE ASSY. 110 5812002121 ALTERNATOR ASSY. 116 9827200690 OIL PRESS. WARNING SW. 116-1 5824100160 OIL PRESS. WARNING SW. 119 9825139288 GLOW PLUG (24V) 420 5197320020 CONNECTOR 123 9825300460 RESISTANCE CONTROLLER 135 5824500141 OVERHEAT SWITCH, M16 135-1 8970299880 OVERHEAT SWITCH, 3/8 178 1819000161 STOP ASSY. .................................. 1 ................... INCL. ITEM W/%79% 1828490430 CABLE ASSY. 1


ISUZU 4BD1 — FEED PUMP COMP. ASSY.

FEED PUMP COMP. ASSY.


ISUZU 4BD1 — FEED PUMP COMP. ASSY.

FEED PUMP COMP. ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 8941327040 FEED PUMP ASSY. .................. 1 ........... INCL. ITEMS W/ #5# 5157510120 PUMP HOUSING 19# 9813512050 PISTON 110# 9813513020 SPRING 111# 9813550230 PLUG 112# 9813550350 GASKET 115# 5157540010 TAPPET ASSY. ......................... 1 ........... INCL. ITEMS W/%16#% 9813514030 ROLLER 117#% 9813514100 PIN 118#% 1157590020 GUIDE 220# 9813517020 SPRING 226# 9813516020 VALVE 227# 1096230160 O RING 131# 5157590270 BOLT 132# 1156190820 BOLT 133# 1157590010 GASKET 135# 1157590030 ADAPTER 137# 5157590120 JOINT 140# 1096230160 O RING 142# 9813550250 SNAP RING 144# 8941311300 PRIMING PUMP ASSY. 1


ISUZU 4BD1 — NOZZLE ASSY.

NOZZLE ASSY.


ISUZU 4BD1 — NOZZLE ASSY.

NOZZLE ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 5153110190 INJ. NOZZLE 42 1153300941 HOLDER ASSY. ........................ 4 ................ INCL. ITEMS W/#4# 5153410010 PUSH ROD 46# 9153430130 SPRING 48# 5153450010 ADJ. SCREW 410# 5153320100 NUT 411# 9153390560 GASKET 412# 9153390570 WASHER 420# 1153320170 RETAINING NUT 421# 5153390030 GASKET 422# 5153510010 CONNECTOR 430# 1153390090 BOLT` 831# 1153390100 GASKET 832# 9153470030 PIN 8


ISUZU 4BD1 — OIL FILTER ASSY.

OIL FILTER ASSY.


ISUZU 4BD1 — OIL FILTER ASSY.

OIL FILTER ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 5132002262 OIL FILTER ASSY. .................... 1 ................ INCL. ITEMS W/#2# 1878102201 OIL FILTER ELEMENT KIT ....... 1 ................ INCL. ITEMS W/&4#& 9099209780 PACKING 15#& 5096230670 PACKING 16#& 9099211950 PACKING 17#& 9132490090 PACKING, UPPER 18# 5132120681 BODY 19# 9132316020 BOLT 110# 9099410980 SPRING 111# 9132390310 SEAT 112# 9098621170 DRAIN PLUG 115# 9000975270 OVER FLOW VALVE 116# 9099408600 SPRING 117# 8941326650 VALVE PLUG 118# 9099205260 PACKING 120# 9132260110 PLUG 121# 9099205260 PACKING 122# 5132110201 CASE 1


ISUZU 4BD1 — FUEL FILTER ASSY.

FUEL FILTER ASSY.


ISUZU 4BD1 — FUEL FILTER ASSY.

FUEL FILTER ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 9132004193 FUEL FILTER ASSY. ................. 1 ................ INCL. ITEMS W/#2# 5878100500 ELEMENT KIT ........................... 1 ................ INCL. ITEMS W/%3#% 9099203270 O RING ELEMENT, UPPER 14#% 9132136010 PACKING 15# 9099208410 O RING 16#% 5096230241 O RING 17# 9095720140 PACKING 28# 1132600470 VALVE 19# 9099203260 PACKING 110#% 9098518100 SPRING SEAT 111# 9099409010 ELEMENT SPRING 112# 9132310660 BOLT 113# 9098620680 DRAIN PLUG 114# 9132111071 CASE 115# 9132128040 COVER 1


ISUZU 4BD1 — ENGINE ACCESSORIES

ENGINE ACCESSORIES


ISUZU 4BD1 — ENGINE ACCESSORIES

ENGINE ACCESSORIES

NO. PART NO. PART NAME QTY. REMARKS1 8944533000 TACHOMETER DRIVE ASSY. 13 1096234650 PACKING 14 0500408200 BOLT 2


PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect orprepaid with the charges added to the invoice.All shipments are F.O.B. point of origin.Multiquip’s responsibility ceases when asigned manifest has been obtained from thecarrier, and any claim for shortage or damagemust be settled between the consignee and thecarrier.

MINIMUM ORDER

The minimum charge for orders from Multiquipis $15.00 net. Customers will be asked forinstructions regarding handling of orders notmeeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and creditwill be allowed, subject to the followingprovisions:

1. A Returned Material Authorization mustbe approved by Multiquip prior to shipment.

2. To obtain a Return Material Authorization,a list must be provided to Multiquip PartsSales that defines item numbers,quantities, and descriptions of the itemsto be returned.

a. The parts numbers and descriptionsmust match the current parts pricelist.

b. The list must be typed or computergenerated.

c. The list must state the reason(s) forthe return.

d. The list must reference the salesorder(s) or invoice(s) under whichthe items were originally purchased.

e. The list must include the name andphone number of the personrequesting the RMA.

3. A copy of the Return MaterialAuthorization must accompany the returnshipment.

PRICING AND REBATES

Prices are subject to change without priornotice. Price changes are effective on a specificdate and all orders received on or after that datewill be billed at the revised price. Rebates forprice declines and added charges for priceincreases will not be made for stock on handat the time of any price change.

Multiquip reserves the right to quote and selldirect to Government agencies, and to OriginalEquipment Manufacturer accounts who useour products as integral parts of their ownproducts.

SPECIAL EXPEDITING SERVICE

A $20.00 to $50.00 surcharge will be added tothe invoice for special handling including busshipments, insured parcel post or in caseswhere Multiquip must personally deliver theparts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under fordamages in excess of the purchase price of theitem with respect to which damages areclaimed, and in no event shall Multiquip beliable for loss of profit or good will or for anyother special, consequential or incidentaldamages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are madein connection with the sale of parts or tradeaccessories nor as to any engine notmanufactured by Multiquip. Such warrantiesmade in connection with the sale of new,complete units are made exclusively by astatement of warranty packaged with suchunits, and Multiquip neither assumes notauthorizes any person to assume for it anyother obligation or liability whatever inconnection with the sale of its products. A partfrom such written statement of warranty, thereare no warranties, express, implied or statutory,which extend beyond the description of theproducts on the face hereof.

4. Freight is at the sender’s expense. Allparts must be returned freight prepaid toMultiquip’s designated receiving point.

5. Parts must be in new and resalablecondition, in the original Multiquip package(if any), and with Muiltiquip part numbersclearly marked.

6. The following items are not returnable:

a. Obsolete parts. (If an item is listedin the parts price book as beingreplaced by another item, it isobsolete.)

b. Any parts with a limited shelf life(such as gaskets, seals, “O” rings,and other rubber parts) that werepurchased more than six monthsprior to the return date.

c. Any line item with an extended dealernet price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7. The sender will be notified of any materialreceived that is not acceptable.

8. Such material will be held for 5 workingdays from notification, pendinginstructions. If a reply is not receivedwithin 5 days, the material will be returnedto the sender at his expense.

9. Credit on returned parts will be issued atdealer net price at time of the originalpurchase, less a 15% restocking charge.

10. In cases where an item is accepted forwhich the original purchase documentcan not be determined, the price will bebased on the list price that was effectivetwelve months prior to the RMA date.

11. Credit issued will be applied to futurepurchases only.

Effective: July 1, 2000 TERMS AND CONDITIONS OF SALE — PARTS


NOTE PAGE

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MULTIQUIP INC..... PARTS DEPARTMENT:18910 WILMINGTON AVE. 800-427-1244CARSON, CALIFORNIA 90746 FAX: 800-672-7877310-537-3700 SERVICE DEPARTMENT:800-421-1244 800-835-2551FAX: 310-537-3927 FAX: 310-638-8046E-mail:[email protected] • www:multiquip.com


HERE'S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBERON-HAND WHEN CALLING

PARTS DEPARTMENT800/427-1244 or 310/537-3700FAX: 800/672-7877 or 310/637-3284

SERVICE DEPARTMENT800/835-2551 or 310/537-3700FAX: 310/638-8046

WARRANTY DEPARTMENT800/835-2551 or 310/537-3700FAX: 310/638-8046

MAIN800/421-1244 or 310/537-3700FAX: 310/537-3927

mq power dca-40ssi whisperwatttm generator · dca-40ssi — parts and operation manual— final...

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